MANUALE STAZIONE DI SERVIZIO

665357(IT) -665358(EN) -665359(FR) -665360(DE)

-665361(ES) -665362(EL) -665363(PT) -665364(NL)

Beverly 300 i.e.

 MANUALE
STAZIONE DI
SERVIZIO

Beverly 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 single
versions should be checked at the official Piaggio sales network.
"© Copyright 2008 - 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. - After-Sales
V.le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi)
 MANUALE STAZIONE DI
SERVIZIO
Beverly 300 i.e.
Questo manuale per stazioni di servizio è stato realizzato da Piaggio & C. Spa per essere utilizzato dalle
officine dei concessionari e sub-agenzie Piaggio-Gilera. 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 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

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
Beverly 300 i.e. Characteristics

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.
- For removal, overhaul and refit operations use only tools with metric measures. Metric bolts, nuts and
screws are not interchangeable with coupling members with English measurement. 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.

CHAR - 7
Characteristics Beverly 300 i.e.

Vehicle identification

Chassis number
To read the chassis number, remove the port A in
the front case.

Engine number
The engine number «B» is stamped near the rear
left shock absorber lower support.

Dimensions and mass

CHAR - 8
Beverly 300 i.e. Characteristics

WEIGHTS AND DIMENSIONS

Specification Desc./Quantity
Length 2150 mm
Width 780 mm
Wheelbase 1535 mm
Height 1190 mm
Kerb weight 171 kg ± 8 kg
Maximum weight allowed 365 kg

Engine

ENGINE
Specification Desc./Quantity
Type Single-cylinder, 4-stroke
Engine capacity 278 cm³
Bore x stroke 75 X 63 mm
Compression ratio 11 ± 0.5: 1
Engine idle speed 1,700 ± 100 rpm
Timing system Four valves, single overhead camshaft, chain-driven.
Valve clearance Intake: 0.10 mm Exhaust: 0.15 mm
Max. power 16.3 kW at 7,250 rpm
MAX. torque 23 Nm at 5,750 rpm
Lubrication Engine lubrication with trochoidal pump (inside the crankcase),
oil filter and pressure adjustment by-pass.
Fuel system 32 MIU1.E9 Electronic injection, with Ø 32-mm throttle body
and electric fuel pump.
Cooling Forced coolant circulation system.
Fuel Unleaded petrol (95 RON)
Silencer Absorption-type exhaust muffler with catalytic converter 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 13 l ± 1

CHAR - 9
Characteristics Beverly 300 i.e.

Electrical system

ELECTRICAL SYSTEM
Specification Desc./Quantity
Starter starter
Ignition Electronic, inductive, high efficiency ignition, integrated with the
injection system, with variable advance and separate HV coil.
Ignition advance Three-dimensional map managed by control unit
Spark plug NGK CR8EKB
Battery SEALED 12V/10Ah
Generator alternating current

Frame and suspensions

WHEELS AND TYRES

Specification Desc./Quantity
Wheel rim type Light alloy wheel rims.
Front wheel rim 3.00" x 16"
Rear wheel rim 3.50" x 14"
Front tyre 110/70 - Tubeless 16" 52S or 52P
Rear tyre 140/70 - Tubeless 14" 68P or 68S
Front tyre pressure (with passenger) 2.2 bar (2.2 bar)
Rear tyre pressure (with passenger) 2.4 bar (2.6 bar)

Brakes

BRAKES
Specification Desc./Quantity
Front brake Ø 300-mm disc brake with hydraulic control activated by han-
dlebar right-side lever.
Rear brake Ø 240-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 3.00" x 16"
Rear wheel rim 3.50" x 14"
Front tyre 110/70 - Tubeless 16" 52S or 52P
Rear tyre 140/70 - Tubeless 14" 68P or 68S
Front tyre pressure (with passenger) 2.2 bar (2.2 bar)
Rear tyre pressure (with passenger) 2.4 bar (2.6 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

CHAR - 10
Beverly 300 i.e. Characteristics

Name Torque in Nm
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
Silencer supporting arm to engine screws (*) 20 to 25
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 fastening pin 19.6 ÷ 24.5
Screw tightening calliper to support 24 ÷ 27
Brake disc screws 8 to 10
Brake fluid tube-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 fastening 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

CHAR - 11
Characteristics Beverly 300 i.e.

Name Torque in Nm
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 - 83
Transmission cover screws 11 to 13
Driven pulley shaft nut 54 ÷ 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
Pick-up 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 4 to 6
shaft) screws
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 to 4
Screws for water pump rotor driving link 3 to 4
Thermostat cover screws 3 to 4
bleed screw: 3

Overhaul data

Assembly clearances

CHAR - 12
Beverly 300 i.e. Characteristics

Cylinder - piston assy.

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

CHAR - 13
Characteristics Beverly 300 i.e.

- 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

- Carefully clean the seal housings.

- Measure the coupling clearance between the
sealing rings and the piston grooves using suitable
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
OF THE FEELER THICKNESS GAUGE FROM THE SECOND
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 clearance 0.015 - 0.06 mm
Middle piston ring - maximum clearance al-
lowed after use 0.07 mm oil scraper ring - stand-
ard coupling clearance 0.015 - 0.06 mm oil scraper
ring - maximum clearance allowed after use
0.07 mm

CHAR - 14
Beverly 300 i.e. Characteristics

- 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 Crankshaft to connecting rod
axial clearance
Crankshaft to connecting rod axial clearance

AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD

Name Description Dimensions Initials Quantity
Transmissionside half- 16.6 +0-0.05 A D = 0.20 ÷ 0.50
shaft
Flywheel-side halfshaft 16.6 +0-0.05 B D = 0.20 ÷ 0.50
Connecting rod 18 -0.10 -0.15 C D = 0.20 ÷ 0.50
Spacer tool 51.4 +0.05 E D = 0.20 ÷ 0.50

Diameter of crankshaft bearings.

Measure the bearings on both axes x-y.

CHAR - 15
Characteristics Beverly 300 i.e.

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

CHAR - 16
Beverly 300 i.e. Characteristics

MAX. ADMISSIBLE DISPLACEMENT

Specification Desc./Quantity
A= 0.15 mm
B= 0.010 mm
C= 0.010 mm
D= 0.10 mm

CHAR - 17
Characteristics Beverly 300 i.e.

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 bushings are available in three thickness categories, identified by colour markings, as shown
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

CHAR - 18
Beverly 300 i.e. Characteristics

COUPLINGS
BUSHING CATEGORY CRANKCASE BUSHING INSIDE DIAMETER AFTER FITTING
HALVES CATEGORY
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:

The identification is indicated on the counterweight shoulder «*1 - *2», if carried out 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).

CHAR - 19
Characteristics Beverly 300 i.e.

If a crankshaft comprising two half-shafts of different categories needs to be replaced, also replace both
crankcase halves, combining the two components (Shaft and Crankcase) featuring the same category.

Cylinder Head

Before performing head service operations, thoroughly clean all coupling surfaces. Note the position of
the springs and the valves so as not to change the original position during refitting

- Using a trued bar and a feeler gauge check that

the cylinder head surface is not worn or distorted.

Characteristic
Maximum allowable run-out:
0.1 mm

- In case of faults, replace the head.

- Check the sealing surfaces for the intake and exhaust manifold.
- Check that the camshaft and the rocking lever pin capacities exhibit no wear.
- Check that the head cover surface is not worn.
- Check that the coolant seal plug exhibits no oxidation.

- Insert the valves into the cylinder head.

- Alternatively check the intake and exhaust
valves.
- The test is carried out by filling the manifold with
petrol and checking that the head does not ooze
through the valves when these are just pressed
with the fingers.

CHAR - 20
Beverly 300 i.e. Characteristics

Measure the camshaft bearing seats and rocking

lever support pins with a bore meter

HEAD BEARINGS
Specification Desc./Quantity
bearing «A» Ø 12.000 - 12.018 mm
bearing «B» Ø 20.000 ÷ 20.021 mm
bearing «C» Ø 37.000 - 37.025 mm

Measure the unloaded spring length

Characteristic
Standard length
40.2 mm
Allowable limit after use:
38.2 mm

- Clean the valve seats of any carbon residues.

- Using the Prussian blue, check the width of the
impression on the valve seat "V".

Characteristic
Standard value:
1 - 1.3 mm
Admissible limit:
1.6 mm

- If the impression width on the valve seat is larger than the prescribed limits, true the seats with a 45°
mill and then grind.
- In case of excessive wear or damage, replace the head.

STANDARD VALVE LENGTH

Specification Desc./Quantity
Valve check Standard length Intake: 94.6 mm
Valve check Standard length Exhaust: 94.4 mm

CHAR - 21
Characteristics Beverly 300 i.e.

- Measure the diameter of the valve stems in the

three positions indicated in the diagram.

STANDARD DIAMETER
Specification Desc./Quantity
Intake: 4.987 - 4.972 mm
Exhaust: 4.975 - 4.960 mm

MINIMUM ADMISSIBLE DIAMETER

Specification Desc./Quantity
Intake: 4.96 mm
Exhaust: 4.945 mm

- Calculate the clearance between valve and valve guide.

- Check the deviation of the valve stem by resting

it on a «V» shaped abutment and measuring the
extent of the deformation with a dial gauge.

Characteristic
Limit values admitted:
0.1 mm

CHAR - 22
Beverly 300 i.e. Characteristics

- Check the concentricity of the valve head by ar-

ranging a dial gauge at right angle relative to the
valve head and rotate it on a "V" shaped abutment.

Characteristic
Admissible limit:
0.03 mm

Measure the valve guide.

Characteristic
Valve guide:
5 +0.012 mm

- After measuring the valve guide diameter and the

valve stem diameter, check clearance between
guide and stem.

INTAKE
Specification Desc./Quantity
Standard clearance: 0.013 - 0.04 mm
Admissible limit: 0.08 mm

OUTLET
Specification Desc./Quantity
Standard clearance: 0.025 to 0.052 mm
Admissible limit: 0.09 mm

- Check that there are no signs of wear on the faying surface with the articulated set screw terminal.

CHAR - 23
Characteristics Beverly 300 i.e.

- If no anomalies are found during the above

checks, you can use the same valves. To obtain
better sealing performance, grind the valve seats.
Grind the valves gently with a fine-grained lapping
compound. During the grinding, keep the cylinder
head with the valve axes in a horizontal position.
This will prevent the lapping compound residues
from penetrating between the valve stem and the
guide (see figure).
CAUTION
TO AVOID SCORING THE FAYING SURFACE, DO NOT KEEP ROTATING THE VALVE WHEN NO
LAPPING COMPOUND IS LEFT. CAREFULLY WASH THE CYLINDER HEAD AND THE VALVES
WITH A SUITABLE PRODUCT FOR THE TYPE OF LAPPING COMPOUND BEING USED.
CAUTION
DO NOT REVERSE THE FITTING POSITIONS OF THE VALVES (RIGHT - LEFT).
- Check that the camshaft bearings exhibit no scores or abnormal wear.
- Using a micrometer, measure the camshaft bearings.

STANDARD DIAMETER
Specification Desc./Quantity
Camshaft check: Standard diameter Bearing A Ø: 36.95 ÷ 36.975 mm
Camshaft check: Standard diameter Bearing B diameter: 19.959 ÷ 19.98 mm

MINIMUM ADMISSIBLE DIAMETER

Specification Desc./Quantity
Camshaft check: Minimum admissible diameter Bearing A Ø: 36.94 mm
Camshaft check: Minimum admissible diameter Bearing B diameter: 19.950 mm

CHAR - 24
Beverly 300 i.e. Characteristics

-Using a gauge, measure the cam height.

STANDARD HEIGHT
Specification Desc./Quantity
Camshaft check: Standard height Intake: 30.285 mm
Camshaft check: Standard height Exhaust: 29.209 mm

Check the axial clearance of the camshaft

CAMSHAFT AXIAL CLEARANCE

Specification Desc./Quantity
Camshaft check: Standard axial clearance: 0.11 - 0.41 mm
Camshaft check: Maximum admissible axial clearance 0.42 mm

- Measure the outside diameter of the rocking lever pins

- Check the rocking lever pins do not show signs of wear or scoring.
- Measure the internal diameter of each rocking lever.
Check there are no signs of wear on the pad from contact with the cam and on the jointed adjustment
plate.

CHAR - 25
Characteristics Beverly 300 i.e.

ROCKING LEVERS AND PIN DIAMETER:

Specification Desc./Quantity
Rocking lever inside diameter: Standard diameter Diameter 12.000 - 12.011 mm
Rocking lever pin diameter: Standard diameter Diameter 11.977 - 11.985 mm

Slot packing system

Characteristic
Compression ratio
10.5 ÷ 11.5 : 1

Measurement "A" to be taken is a value of piston re-entry, it indicates by how much the plane formed
by the piston crown falls below the plane formed by the top of the cylinder. The further the piston falls
inside the cylinder, the less the base gasket to be applied (to recover the compression ratio) and vice
versa.

CHAR - 26
Beverly 300 i.e. Characteristics

N.B.
MEASUREMENT "A" MUST BE TAKEN WITHOUT ANY GASKET FITTED BETWEEN THE CRANK-
CASE AND CYLINDER AND AFTER RESETTING THE DIAL GAUGE, EQUIPPED WITH A SUP-
PORT, ON A GROUND PLANE

ENGINE 300 SHIMMING

Name Measure A Thickness
SHIMMING 3.70 - 3.60 0.4 ± 0.05
SHIMMING 3.60 - 3.40 0.6 ± 0.05
SHIMMING 3.40 - 3.30 0.8 ± 0.05

Products

RECOMMENDED PRODUCTS TABLE

Product Description Specifications
AGIP ROTRA 80W-90 Rear hub oil SAE 80W/90 Oil that exceeds the re-
quirements of API GL3 specifications
AGIP CITY HI TEC 4T Oil to lubricate flexible transmissions Oil for 4-stroke engines
(throttle control)
AGIP FILTER OIL Oil for air filter sponge Mineral oil with specific additives for in-
creased adhesiveness
AGIP GP 330 Grease for brake lever, gas White calcium complex soap-based
spray grease with NLGI 2; ISO-L-XBCIB2
AGIP CITY HI TEC 4T Engine oil SAE 5W-40, API SL, ACEA A3, JASO MA
Synthetic oil
AGIP BRAKE 4 Brake fluid FMVSS DOT 4 Synthetic fluid
AGIP PERMANENT SPEZIAL coolant Monoethylene glycol-based antifreeze
fluid, CUNA NC 956-16

UNIT OF MEASURE - CONVERSION - ENGLISH SYSTEM TO INTERNATIONAL SYSTEM (IS).

Specification Desc./Quantity
1 Inch (in) 25.4 Millimetres (mm)
1 Foot (ft) 0.305 Metres (m)
1 Mile (mi) 1.609 Kilometres (km)
1 US Gallon (USgal) 3.785 Litres (l)
1 Pound (lb) 0.454 Kilograms (kg)
1 Cubic inch (in³) 16.4 Cubic centimetres (cm³)
1 Foot pound (ft lb) 1,356 Newton metres (Nm)
1 Mile per hour (mi/h) 1.602 Kilometres per hour (km/h)
1 Pound per square inch (PSI) 0.069 (bar)
1 Fahrenheit (°F) 32+(9/5) Celsius (°C)

CHAR - 27
INDEX OF TOPICS

TOOLING TOOL
Beverly 300 i.e. Tooling

SPECIFIC TOOLS
Stores code Description
001330Y Tool for fitting steering seats

001467Y014 Calliper to extract ø 15-mm bearings

005095Y Engine support

002465Y Calliper for circlips

006029Y Punch for fitting steering bearing seat on

steering tube

020004Y Punch for removing steering bearings

from headstock

020055Y Wrench for steering tube ring nut

TOOL - 29
Tooling Beverly 300 i.e.

Stores code Description

020074Y Support base for checking crankshaft
alignment

020150Y Air heater mounting

020151Y Air heater

020193Y Oil pressure check gauge

020262Y Crankcase splitting plate

020263Y Driven pulley assembly sheath

TOOL - 30
Beverly 300 i.e. Tooling

Stores code Description

020306Y Punch for assembling valve seal rings

020329Y Mity-Vac vacuum-operated pump

020330Y Stroboscopic light to check timing

020331Y Digital multimeter

020332Y Digital rpm indicator

TOOL - 31
Tooling Beverly 300 i.e.

Stores code Description

020648Y Single battery charger

020335Y Magnetic mounting for dial gauge

020357Y 32x35-mm Adaptor

020359Y 42x47-mm Adaptor

020360Y 52x55-mm Adaptor

020363Y 20-mm guide

TOOL - 32
Beverly 300 i.e. Tooling

Stores code Description

020375Y 28 x 30 mm adaptor

020376Y Adaptor handle

020382Y Valve cotters equipped with part 012 re-

moval tool

020382Y011 adapter for valve removal tool

020393Y Piston assembly band

020412Y 15-mm guide

TOOL - 33
Tooling Beverly 300 i.e.

Stores code Description

020423Y Driven pulley lock wrench

020424Y Driven pulley roller casing fitting punch

020426Y Piston fitting fork

020431Y Valve oil seal extractor

020434Y Oil pressure check fitting

020444Y Tool for fitting/ removing the driven pulley

clutch

TOOL - 34
Beverly 300 i.e. Tooling

Stores code Description

020456Y Ø 24 mm adaptor
020477Y 37 mm adaptor

020483Y 30-mm guide

020489Y Hub cover support stud bolt kit

020428Y Piston position check mounting

020680Y Diagnosis Tool

TOOL - 35
Tooling Beverly 300 i.e.

Stores code Description

020621Y HV cable extraction adaptor

020481Y Control unit interface wiring

001467Y035 Bearing housing, out ø 47 mm

020626Y Driving pulley lock wrench

001467Y013 Calliper to extract ø 15-mm bearings

020627Y Flywheel lock wrench

TOOL - 36
Beverly 300 i.e. Tooling

Stores code Description

020467Y Flywheel extractor

020454Y Tool for fitting piston pin stops (200 - 250)

020622Y Transmission-side oil seal punch

020480Y Petrol pressure check kit

020244Y 15-mm diameter punch

020115Y Ø 18 punch

TOOL - 37
Tooling Beverly 300 i.e.

Stores code Description

020271Y Tool for removing-fitting silent bloc

020638Y 250 l ENGINE SOFTWARE E. - ABS

020469Y Reprogramming kit for scooter diagnostic

tester

020487Y Fork oil seal extractor

020458Y Puller for lower bearing on steering tube

TOOL - 38
INDEX OF TOPICS

MAINTENANCE MAIN
Maintenance Beverly 300 i.e.

RESET SERVICE WARNING LIGHT

At vehicle ignition, immediately after the ignition
check, if there are less than 300 km (187.5 miles)
to the next scheduled service, the corresponding
icon flashes for 5 seconds. Once the service mile-
age has been reached, the icon remains steadily
on until it is reset.
The service is reset by holding down the MODE
button to the key connection for more than 10 sec-
onds; for the first 5 seconds, the instrument panel
will not give any signal; for the next 5 seconds the
key icon will blink at frequency of 1 Hz. If the button
is released before 10 seconds, the service is not
reset.

Maintenance chart

MAINTENANCE TABLE
I: INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE, IF NECESSARY C: CLEAN, R: REPLACE, A: ADJUST, L:
LUBRICATE
* Replace every 2 years
** Clean frequently in cases of intensive use on gravel roads

Km x 1,000 1 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80
Driven pulley roller casing L L L L L L L L
Safety fasteners I I I I I
Ignition spark plug R R R R R R R R
Centre stand bracket L L L L L L L L L L L L L L L L
Drive belt R R R R R
Throttle control A A A A A A A A A
Air filter/CVT filter ** C C C C C C C C
Oil filter R R R R R R R R R
Valve clearance A A A A
Electrical system and battery I I I I I I I I I
Coolant level * I I I I I I I I I
Brake fluid * I I I I I I I I I
Engine oil R I R I R I R I R I R I R I R I R
Hub oil R I R I R I R I R
Brake pads I I I I I I I I I I I I I I I I I
Sliding shoes / CVT rollers R R R R R R R R
Tyre pressure and wear I I I I I I I I I
Vehicle road test I I I I I I I I I
Suspension I I I I I I I I I
Steering A I I I I I I I I
Time 60' 10' 10 45' 15 10' 14 10' 15 45' 10 10' 19 10' 10 45' 15
0' 0' 0' 0' 0' 0' 0' 0'

MAIN - 40
Beverly 300 i.e. Maintenance

Spark plug

Proceed as follows:
- Remove the case that grants access to the spark
plug located on the right side fairing by unscrewing
the indicated screw.
- Disconnect cap «A» from the spark plug HV ca-
ble by turning it clockwise until releasing it from the
retainer.
- Unscrew the spark plug using the wrench sup-
plied.
- When refitting, place the spark plug into the hole
at the corresponding angle and finger tighten it as
far as it will go. Use the wrench only to tighten it.
- Place cap «A» fully over the spark plug, making
sure it is in the retainer again.
WARNING

SPARK PLUG MUST BE REMOVED WHEN THE ENGINE IS

COLD. REPLACE THE SPARK PLUG AS INDICATED IN
THE SCHEDULED MAINTENANCE TABLE. THE USE OF
ELECTRONIC CENTRAL UNITS AND OF NON-COMPLIANT
ELECTRONIC IGNITIONS OR SPARK PLUGS OTHER
THAN THOSE PRESCRIBED MAY SERIOUSLY DAMAGE
THE ENGINE.
N.B.
USE OF SPARK PLUGS OTHER THAN THE INDICATED
TYPE OR UNSHIELDED SPARK PLUG CAPS CAN LEAD
TO FAULTS IN THE VEHICLE 'S ELECTRICAL SYSTEM.

Hub oil

Check

-Place the vehicle on the centre stand on flat

ground;
- Remove the oil dipstick «A», dry it with a clean
cloth and put it back into its hole tightening it
completely;
Remove the dipstick and check that the oil level is
slightly over the second notch starting from the
lower end; if the level is under the MAX. mark, it
needs to be filled with the right amount of hub oil.

MAIN - 41
Maintenance Beverly 300 i.e.

-Screw up the oil dipstick again and make sure it

is locked properly into place.

Replacement

-Remove the oil filler cap «A».

- Unscrew the oil drainage cap «B» and drain out
all the oil.
- Screw in the drainage cap again and fill the hub
with the prescribed oil.

Recommended products
AGIP ROTRA 80W-90 Rear hub oil
SAE 80W/90 Oil that exceeds the requirements of
API GL3 specifications

Characteristic
Rear hub oil
Capacity approximately 250 cc

Locking torques (N*m)

Hub oil drainage screw 15 to 17 Nm

Air filter

To access the air filter:

- Unscrew the three screws «A» and remove the
air filter cover.
- Unscrew the other six screws «B» and remove
the air filter cover.

MAIN - 42
Beverly 300 i.e. Maintenance

1. Wash the sponge with water and neutral soap.

2. Dry it with a clean cloth and small blasts of com-
pressed air.
3. Soak the sponge with a mixture of 50% petrol
and 50% specified oil.
4. Gently squeeze the filter element without twist-
ing it, let it drip and then refit it.
CAUTION

IF THE VEHICLE IS USED ON DUSTY ROADS IT IS NEC-

ESSARY TO CARRY OUT MAINTENANCE CHECKS OF
THE AIR FILTER MORE OFTEN TO AVOID DAMAGING THE
ENGINE.

Recommended products
AGIP FILTER OIL Oil for air filter sponge
Mineral oil with specific additives for increased ad-
hesiveness

Engine oil

Replacement

Change oil and replace filter as indicated in the

scheduled maintenance table.
- In order to facilitate oil drainage, unscrew the cap/
dipstick «A».

MAIN - 43
Maintenance Beverly 300 i.e.

- Unscrew the mesh pre-filter drainage plug «B»

on the flywheel side and let the oil drain off.
- Once all the oil has drained through the drainage
hole, unscrew and remove the oil cartridge filter
«C ».

Make sure the pre-filter and drainage plug O-rings

are in good conditions. Lubricate them and refit the
mesh filter and the oil drainage plug, screwing
them up to the prescribed torque.
Refit the new cartridge filter being careful to lubri-
cate the O-ring before fitting it.
Add the recommended engine oil through plug
«A». Then start up the vehicle, let it run for a few
minutes and shut it off. After five minutes check the
level and if necessary top up without exceeding the
MAX level. The cartridge filter must be replaced
every time the oil is changed.
N.B.
THE ENGINE MUST BE HOT WHEN THE OIL IS CHANGED.

Recommended products
AGIP CITY HI TEC 4T Engine oil
SAE 5W-40 Synthetic oil that exceed the require-
ments of API SL, ACEA A3, JASO MA specifica-
tions

Characteristic
Engine oil
1.3 l

MAIN - 44
Beverly 300 i.e. Maintenance

Check

This operation must be carried out with the en-

gine cold and following the procedure below:
- Place the vehicle on its centre stand and on flat
ground.
- Make sure the adjustment of the rear suspension
is set to the minimum preloading position.
- Unscrew the cap/dipstick «A», dry it with a clean
cloth and reinsert it, by screwing it in complete-
ly.
-Remove the cap/dipstick «A» again and check
that the level is between the MAX and MIN marks.
top-up, if required.
If the check is carried out after the vehicle has
been used, and therefore with a hot engine, the
level line will be lower; in order to carry out a cor-
rect check, wait at least 10 minutes after the en-
gine has been stopped so as to get the correct
level.

Oil top-up
The oil should be topped up after having checked the level and in any case by adding oil without ex-
ceeding the MAX level indicated on the cap/ dipstick.Restoring the level from MIN to MAX requires
approximately 400 cm³ of oil.

Engine oil filter

The cartridge filter must be replaced every time the oil is changed. Use new oil of the recommended
type for topping up and changing purposes.
Make sure the pre-filter and drainage plug O-rings are in good conditions. Lubricate them and refit the
mesh filter and the oil drainage plug, screwing them up to the prescribed torque. Refit the new cartridge
filter being careful to lubricate the O-ring before fitting it. Change the engine oil.

Recommended products
AGIP CITY HI TEC 4T Engine oil
SAE 5W-40 Synthetic oil that exceed the requirements of API SL, ACEA A3, JASO MA specifications

MAIN - 45
Maintenance Beverly 300 i.e.

Oil pressure warning light

The vehicle is equipped with a telltale light on the

dashboard that lights up when the key is turned to
the «ON» position. However, this light should
switch off once the engine has been started.
If the light turns on during braking, at idling
speed or while turning a corner, it is necessary
to check the oil level and the lubrication sys-
tem.

Cooling system

Level check

Check coolant when the engine is cold and as in-

dicated in the scheduled maintenance tables, fol-
lowing the steps below.
- Set the vehicle upright on the stand and remove
the cover by undoing screw «A».

- Remove the expansion tank cover «B» by turning

it anticlockwise.

MAIN - 46
Beverly 300 i.e. Maintenance

- Look inside the expansion tank and check that

the level is between MIN and MAX. Top up if the
coolant is below the MIN level.
If the level is not correct, proceed to top-up when
the engine is cold. If it is necessary to top up the
coolant frequently, or if the expansion tank is com-
pletely dry, you should look for the cause in the
cooling system.
WARNING

TO AVOID THE RISK OF SCALDING, DO NOT UNSCREW

THE EXPANSION TANK COVER WHILE THE ENGINE IS
STILL HOT.
WARNING

IN ORDER TO AVOID HARMFUL FLUID LEAKS WHILE RID-

ING, IT IS IMPORTANT TO MAKE SURE THAT THE LEVEL
DOES NOT EXCEED THE REFERENCE TONGUE TOO
MUCH.
TO ENSURE CORRECT ENGINE OPERATION, KEEP THE
RADIATOR GRILLE CLEAN.

Recommended products
AGIP PERMANENT SPEZIAL coolant
Monoethylene glycol-based antifreeze fluid, CU-
NA NC 956-16

Braking system

Level check

The front and rear brake fluid reservoirs are both

positioned on the handlebar. Proceed as follows:
- Rest the vehicle onto the centre stand, with the
handlebar centred.
- Check the fluid level through the sight glass
«A».
A certain lowering of the level is caused by wear
on the brake pads.

MAIN - 47
Maintenance Beverly 300 i.e.

Top-up

For topping-up, proceed as follows:

- Remove the mirrors unscrewing them from their
seats
- Unscrew the two screws «A» and remove the
pressure covering.
- Unscrew the two screws «B» and, working on
both sides of the vehicle, unscrew the screw «C».
- Using a flat-headed screwdriver, detach the fas-
tener tab as shown in the figure, accessing the tab
via the indicated slit.
- Insert the screwdriver between the two covers,
as indicated in the figure, and detach the upper
fastener tab. Move the rear handlebar cover aside.
- Unscrew the two screws «D» and remove the
front handlebar cover releasing the front headlight
connector
- Unscrew the two screws «E» and remove the cap
«F» of the brake pump to top up to the optimum
level.
WARNING
BRAKING CIRCUIT FLUID IS HIGHLY CORROSIVE; DO
NOT LET IT COME INTO CONTACT WITH PAINTED PARTS.
CAUTION
ONLY USE DOT 4-CLASSIFIED BRAKE FLUID.
WARNING
THE BRAKE FLUID IS HAZARDOUS: IN CASE OF ACCI-
DENTAL CONTACT, WASH OFF WITH WATER.
WARNING
THE BRAKING CIRCUIT LIQUID IS HYGROSCOPIC, AND
ABSORBS THE HUMIDITY OF SURROUNDING AIR. IF THE
HUMIDITY IN THE BRAKING FLUID EXCEEDS A CERTAIN
VALUE, IT WILL LEAD TO INEFFICIENT BRAKING. NEVER
USE BRAKING FLUID KEPT IN CONTAINERS THAT HAVE
ALREADY BEEN OPENED, OR PARTIALLY USED.

Recommended products
Brake fluid Brake fluid
FMVSS DOT 4 Synthetic fluid

MAIN - 48
Beverly 300 i.e. Maintenance

MAIN - 49
Maintenance Beverly 300 i.e.

Headlight adjustment

Proceed as follows:
- Position the vehicle in running order and with the
tyres inflated to the prescribed pressure, onto a flat
surface, 10 m away from a half-lit white screen;
ensure that the longitudinal axis of the vehicle is
perpendicular to the screen;
- Turn on the headlight and check that the border-
line of the projected light beam on the screen is not
higher than 9/10 or lower than 7/10 of the distance
from the ground to the centre of the vehicle head-
lamp;
- Otherwise, adjust the headlight. Unscrew the two
screws «A» and remove the pressure covering.
Screw in the screw «B» to lower the light beam,
unscrew the screw «B» to raise the light beam.
N.B.
THE ABOVE PROCEDURE COMPLIES WITH THE EURO-
PEAN STANDARDS REGARDING MAXIMUM AND MINI-
MUM HEIGHT OF LIGHT BEAMS. REFER TO THE STATU-
TORY REGULATIONS IN FORCE IN EVERY COUNTRY
WHERE THE VEHICLE IS USED.

MAIN - 50
INDEX OF TOPICS

TROUBLESHOOTING TROUBL
Troubleshooting Beverly 300 i.e.

This section makes it possible to find what solutions to apply when troubleshooting.
For each failure, a list of the possible causes and pertaining operations is given.

Engine

Poor performance

POOR PERFORMANCE
Possible Cause Operation
Fuel pump Check the injection load relay
Excess of scales in the combustion chamber Descale the cylinder, the piston, the head and the valves
Incorrect timing or worn timing system elements Time the system again or replace the worn parts
Silencer obstructed Replace
Air filter blocked or dirty. Remove the sponge, wash with water and car shampoo, then
soak it in a mixture of 50% petrol and 50% specific oil. Press
with your hand without squeezing, allow it to drip dry and refit.
Oil level exceeds maximum Check for causes and fill to reach the correct level
Lack of compression: parts, cylinder and valves worn Replace the worn parts
Drive belt worn Replace
Inefficient automatic transmission Check the rollers, the pulley movement and make sure the
drive belt is in good conditions; replace the damaged parts and
lubricate the moveable driven pulley with specific grease.
Clutch slipping Check the clutch system and/or the bell and replace if neces-
sary
Overheated valves Remove the head and the valves, grind or replace the valves
Wrong valve adjustment Adjust the valve clearance properly
Valve seat distorted Replace the head unit

Starting difficulties

DIFFICULT STARTING
Possible Cause Operation
Rpm too low at start-up or engine and start-up system dam- Check the starter motor, the system and the torque limiter
aged
Incorrect valve sealing or valve adjustment Inspect the head and/or restore the correct clearance
Engine flooded Try starting-up with the throttle fully open. If the engine fails to
start, remove the spark plug, dry it and before refitting, make
the engine turn so as to expel the fuel excess taking care to
connect the cap to the spark plug, and this in turn to the ground.
If the fuel tank is empty, refuel and start up.
Air filter blocked or dirty. Remove the sponge, wash with water and car shampoo, then
soak it in a mixture of 50% petrol and 50% specific oil. Press
with your hand without squeezing, allow it to drip dry and refit.
Faulty spark plug or incorrect ignition advance Replace the spark plug or check the ignition circuit components
Flat battery Check the charge of the battery, if there are any sulphur marks,
replace and use the new battery following the instructions
shown in the chapter
Intake coupling cracked or clamps incorrectly tightened Replace the intake coupling and check the clamps are tight-
ened

Excessive oil consumption/Exhaust smoke

EXCESSIVE CONSUMPTION
Possible Cause Operation
Wrong valve adjustment Adjust the valve clearance properly
Overheated valves Remove the head and the valves, grind or replace the valves

TROUBL - 52
Beverly 300 i.e. Troubleshooting

Possible Cause Operation

Misshapen/worn valve seats Replace the head unit
Worn cylinder, Worn or broken piston rings Replace the piston cylinder assembly or piston rings
Worn or broken piston rings or piston rings that have not been Replace the piston cylinder unit or just the piston rings
fitted properly
Oil leaks from the couplings or from the gaskets Check and replace the gaskets or restore the coupling seal
Worn valve oil seal Replace the valve oil seal
Worn valve guides Check and replace the head unit if required

Insufficient lubrication pressure

POOR LUBRICATION PRESSURE

Possible Cause Operation
By-Pass remains open Check the By-Pass and replace if required. Carefully clean the
By-Pass area.
Oil pump with excessive clearance Perform the dimensional checks on the oil pump components
Oil filter too dirty Replace the cartridge filter
Oil level too low Restore the level adding the recommended oil type

Transmission and brakes

Clutch grabbing or performing inadequately

IRREGULAR CLUTCH PERFORMANCE OR SLIPPAGE

Possible Cause Operation
Faulty clutch Check that there is no grease on the masses. Check that the
clutch mass faying surface with the bell is mainly in the centre
with equivalent characteristics on the three masses. Check that
the clutch casing is not scored or worn in an anomalous way

Insufficient braking

INEFFICIENT BRAKING SYSTEM

Possible Cause Operation
Inefficient braking system Check the pad wear (1.5 min). Check that the brake discs are
not worn, scored or warped. Check the correct level of fluid in
the pumps and change brake fluid if necessary. Check there is
no air in the circuits; if necessary, bleed the air. Check that the
front brake calliper moves in axis with the disc.
Fluid leakage in hydraulic braking system Failing elastic fittings, plunger or brake pump seals, replace
Brake disc slack or distorted Check the brake disc screws are locked; measure the axial shift
of the disc with a dial gauge and with wheel mounted on the
vehicle.

Brakes overheating

BRAKE OVERHEAT
Possible Cause Operation
Defective plunger sliding Replace the calliper.
Brake disc slack or distorted Check the brake disc screws are locked; use a dial gauge and
a wheel mounted on the vehicle to measure the axial shift of
the disc.
Clogged compensation holes on the pump Clean carefully and blast with compressed air
Swollen or stuck rubber gaskets Replace the calliper.

TROUBL - 53
Troubleshooting Beverly 300 i.e.

Steering and suspensions

Heavy steering

STEERING HARDENING
Possible Cause Operation
Steering hardening Check the tightening of the top and bottom ring nuts. If irregu-
larities continue in turning the steering even after making the
above adjustments, check the rotation seats and the steering
fifth wheels.

Excessive steering play

EXCESSIVE STEERING CLEARANCE

Possible Cause Operation
Torque not conforming Check the tightening of the top and bottom ring nuts. If irregu-
larities continue in turning the steering even after making the
above adjustments, check the rotation seats and the steering
fifth wheels.

Noisy suspension

NOISY SUSPENSION
Possible Cause Operation
Malfunctions in the suspension system If the front suspension is noisy, check: tightening torques,
headstock components, inspect forks.

Suspension oil leakage

OIL LEAKAGE FROM SUSPENSION

Possible Cause Operation
Faulty or broken seals Replace the shock absorber

TROUBL - 54
INDEX OF TOPICS

ELECTRICAL SYSTEM ELE SYS

Electrical system Beverly 300 i.e.

Components arrangement

1. Starter switch: remove the legshield to reach

them.
2. Immobilizer antenna: remove the legshield to
reach them.
3. Regulator connector: remove the legshield to
reach them.

4. Spark plug: remove the spark plug inspection

cover to access the spark plug.

ELE SYS - 56
Beverly 300 i.e. Electrical system

5. Battery: lift the saddle and remove the battery

cover to access the battery.
6. Fuses: lift the saddle and remove the battery
cover to access the battery.
7. Solenoids: lift the saddle and remove the battery
cover to access the battery.
8. Diagnostic socket: lift the saddle and remove the
battery cover to access the battery.

9. ECU: lift the saddle and remove the engine in-

spection cover to access the ECU.

10. Saddle actuator: to reach it, remove the left

fairing.

11. HV coil: remove the helmet compartment to

reach it.

ELE SYS - 57
Electrical system Beverly 300 i.e.

12. Start-up solenoid: to reach it, remove the left

fairing.

13. Stand button: remove the left footrest to reach

it.

14. Stator connector: remove the central chassis

cover to reach them.
15. Fall sensor: remove the central chassis cover
to reach them.
16. Fuel pump: remove the central chassis cover
to reach them.
17. Fuel level transmitter: remove the central chas-
sis cover to reach them.

18. Horn: remove the front wheel housing to reach

it.

ELE SYS - 58
Beverly 300 i.e. Electrical system

19. Temperature sensor: remove the legshield to

reach them.
20. LV socket: remove the legshield to reach them.

21. Regulator: remove the legshield to reach them.

22. Turn indicator device: remove the legshield to
reach them.

Instrument panel

A= High beam warning light

B = Turn indicator warning lights
C = Fuel gauge

ELE SYS - 59
Electrical system Beverly 300 i.e.

D = Low fuel warning light

E = Speedometer
F = Immobiliser LED
G = Coolant temperature gauge
H = Engine control telltale light
I = Engine oil pressure warning light
L = Digital display

Ground points

- Frame ground points «A» and «B». Remove the

left footrest to reach them.
- Engine ground point «C»

Electrical system installation

ELE SYS - 60
Beverly 300 i.e. Electrical system

Front side

1. Ignition switch hood

2. Turn indicator control device
3. Voltage regulator
4. Side stand switch
5. Overturn sensor
6. HV coil
7. Front L turn indicator and daylight running lights

ELE SYS - 61
Electrical system Beverly 300 i.e.

1. Electric fan connection

2. Side stand connection
3. Overturn sensor
4. HV coil
5. Stator connection

ELE SYS - 62
Beverly 300 i.e. Electrical system

1. Immobilizer aerial
2. Low voltage power socket accessories in the front top box
3. To the front right turn indicator and daylight running lights
4. External air temperature sensor
5. Boost cable connection (only in version 125)
6. Flywheel - regulator connection
7. To instrument panel
8. To headlight
9. To the left stop button
10.to the right stop button
11.Horn
12.Fuel pump connection
13.Voltage regulator

ELE SYS - 63
Electrical system Beverly 300 i.e.

Back side

1. License plate light connection

2. To the right headlamp
3. To the right turn indicator
4. Helmet compartment lighting to the light unit
5. Pick-up connection
6. Flywheel cables
7. Cables to the motor
8. To the license plate lightening

ELE SYS - 64
Beverly 300 i.e. Electrical system

1. Starter relay
2. To the fuse holder terminal block
3. To battery positive
4. To the starter relay
5. Ground point
6. Starter motor positive cable
7. Saddle opening actuator

ELE SYS - 65
Electrical system Beverly 300 i.e.

1. To the left turn indicator

2. To the left headlamp
3. License plate light connection
4. To the right turn indicator
5. To the right headlamp
6. Micro-relay
7. Rear fuse-box

ELE SYS - 66
Beverly 300 i.e. Electrical system

8. Diagnostics socket
9. Negative battery pole
10.Battery 12V 10Ah
11.Helmet compartment light switch
12.Positive battery pole

Conceptual diagrams

BASIC CIRCUIT DIAGRAM LEGEND:

1. F01-30A
2.F02-15A
3. F03-10A
4.F04-15A
5.Starter switch
6.F05-10A
7.F06-5A
8.Starter solenoid
9.Starter motor
10.12V - 10Ah Battery
11.Chassis ground
12. Regulator

ELE SYS - 67
Electrical system Beverly 300 i.e.

13. Flywheel
14. Antitheft
15. Provision for actuator control receiver
16.Antitheft
17.Reset receiver radio
18.Saddle button
19.Actuator
20.LV socket
21.Helmet compartment light button
22.Light unit
23.Rear right turn indicator
24.Rear left turn indicator
25.Front right hand turn indicator
26.Front left hand turn indicator
27.Antitheft
28.Turn indicator warning light
29.Turn indicator switch
30. turn indicator control
31.Low beam light bulb
32.High beam light bulb
33.High beam indicator light
34.Light switch
35.Headlight solenoid
36.Electronic control unit
37.Instrument panel
38.Fuel gauge
39.Engine temperature sensor
40.Ambient temperature sensor
41.Speed sensor
42.Mode button
43.Electric fan
44.Immobilizer aerial
45.Electric fan solenoid
46.Starter button
47.Right hand stop light bulb
48.Left hand stop light bulb
49.Stop button
50.Stop button

ELE SYS - 68
Beverly 300 i.e. Electrical system

51.License plate lighting bulb

52.Horn
53.Horn button
54.Rear right hand turn indicator bulb
55.Rear left hand turn indicator bulb
56.Front right hand turn indicator bulb
57.Front left hand turn indicator bulb
58.Injection load solenoid
59.Fuel pump
60.Engine stop switch
61.Stand button (raised position)
62.HV coil
63.Water pump (125ie version only)
64.Diagnostics socket
65.Fuel injector
66.Overturn sensor
67.Lambda probe
68.Pickup
69.Oil pressure sensor

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Ignition

BASIC CIRCUIT DIAGRAM LEGEND:

1. F01-30A
3. F03-10A
4.F04-15A
5.Starter switch
6.F05-10A
7.F06-5A
10.12V - 10Ah Battery
11.Chassis ground
36.Electronic control unit
37.Instrument panel
43.Electric fan
58.Injection load solenoid
60.Engine stop switch
61.Stand button (raised position)
62.HV coil

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Battery recharge and starting

BASIC CIRCUIT DIAGRAM LEGEND:

1. F01-30A
5.Starter switch
6.F05-10A
8.Starter solenoid
9.Starter motor
10.12V - 10Ah Battery
11.Chassis ground
12. Regulator
13. Flywheel
36.Electronic control unit
46.Starter button
47.Right stop light bulb
48.Left stop light bulb
49.Stop button
50.Stop button

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Level indicators and enable signals section

BASIC CIRCUIT DIAGRAM LEGEND:

1. F01-30A
2.F02-15A
3. F03-10A
4.F04-15A
5.Starter switch
6.F05-10A
7.F06-5A
10.12V - 10Ah Battery
36.Electronic control unit
37.Instrument panel
38.Fuel gauge
39.Engine temperature sensor
44.Immobilizer aerial
58.Injection load solenoid
60.Engine stop switch
61.Stand button (raised position)
65.Fuel injector

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67.Lambda probe
68.Pickup
69.Oil pressure sensor

Devices and accessories

BASIC CIRCUIT DIAGRAM LEGEND:

1. F01-30A
2.F02-15A
3. F03-10A
4.F04-15A
5.Starter switch
6.F05-10A
7.F06-5A
10.12V - 10Ah Battery
14. Antitheft
15. Provision for actuator control receiver
16.Antitheft
17.Reset receiver radio
18.Saddle button
19.Actuator

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20.LV socket
21.Helmet compartment light button
22.Light unit
37.Instrument panel
40.Ambient temperature sensor
41.Speed sensor
42.Mode button
43.Electric fan
45.Electric fan solenoid
52.Horn
53.Horn button
58.Injection load solenoid
59.Fuel pump
63.Water pump (125ie version only)
64.Diagnostics socket
66.Overturn sensor

Lights and turn indicators

BASIC CIRCUIT DIAGRAM LEGEND:

1. F01-30A

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4.F04-15A
5.Starter switch
6.F05-10A
7.F06-5A
10.12V - 10Ah Battery
11.Chassis ground
23.Rear right turn indicator
24.Rear left turn indicator
25.Front right turn indicator
26.Front left turn indicator
27.Antitheft
28.Turn indicator warning light
29.Turn indicator switch
30. turn indicator control
31.Low beam light bulb
32.High beam light bulb
33.High beam warning light
34.Light switch
35.Headlight solenoid
36.Electronic control unit
46.Starter button
47.Right stop light bulb
48.Left stop light bulb
49.Stop button
50.Stop button
51.License plate lighting bulb
54.Rear right turn indicator bulb
55.Rear left turn indicator bulb
56.Front right turn indicator bulb
57.Front left turn indicator bulb

Checks and inspections

This section is dedicated to the checks on the electrical system components.

Immobiliser
The electronic ignition system is controlled by the control unit with the integrated Immobilizer system.
The immobilizer is an anti-theft system that allows the vehicle to be operated only when it is started with
coded keys recognised by the control unit. The code is integrated in a transponder in the key block.

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This allows the driver clear operation without having to do anything other than just turning the key. The
Immobilizer system consists of the following components:
- an electronic control unit
- immobilizer aerial
- master key with built-in transponder
- service key with built-in transponder
- diagnosis LED
The diagnosis LED also works as a theft-deterrent blinker. This function is activated every time the key
switch is set to «OFF» or the engine emergency cut-off switch is set to «OFF». It remains activated for
48 hours in order not to affect the battery charge. When the ignition switch is turned to «ON», the
deterring blinker function is deactivated. Subsequently, a flash confirms the switching to « ON». The
duration of the flash depends on the programming of the electronic control unit If the LED is off regard-
less of the position of the ignition-key switch and/or the instrument panel is not initiated, check if:
- there is battery voltage
- fuses No. 1; 2; 6 and 9 are in working order
- there is power to the control unit as specified below:

2 With the key switch set to OFF:

- if there is battery voltage between terminals 6-26
and terminal 6-chassis ground (fixed power sup-
ply). If there is no voltage, check that fuse 6 and
its cable harness are in working order.

With the key switch in the OFF position:

- if there is battery voltage between terminals 5-26
and terminals 5-chassis ground (fixed power sup-
ply). If there is no voltage, check the key switch
contacts, and that fuses No. 1 and 9 and their ca-
ble harnesses are in working order.

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- There is continuity between terminals 12-18 and

the emergency cut-off switch is set to «RUN» and
the side stand is folded up. If there is no continuity,
check the contacts of the latter.

After removing the leg shield back plate, remove

the electrical connection from the aerial as shown
in the picture.

Remove the protective base from the connector.

With the ignition key switch at «ON» check if there is battery voltage between the Red-White and Black
cables

With MIU connector disconnected, check the con-

tinuity between the Orange-White cable and pin 7
of the interface wiring.

Specific tooling
020481Y Control unit interface wiring
020331Y Digital multimeter

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Virgin circuit

When the ignition system is not encrypted, any key will start the engine but limited to 2000 rpm. The
keys can only be recognised if the control unit has been programmed properly. The data storage pro-
cedure for a previously not programmed control unit provides for the recognition of the Master as the
first key to be stored to memory: this becomes particularly important because it is the only key that
enables the control unit to be wiped clean and reprogrammed for the memorisation of the service keys.
The Master and service keys must be used to code the system as follows:
- Insert the Master key, turn it to «ON» and keep this position for two seconds (limit values 1 to 3
seconds).
- Insert the service key and turn it to «ON» for 2 seconds.
- If you have copies of the key, repeat the operation with each key.
- Insert the MASTER key again and turn it to «ON» for 2 seconds.
The maximum time to change keys is 10 seconds.
A maximum of 7 service keys can be programmed at one time.
It is essential to adhere to the times and the procedure. If you do not, start again from the beginning.
Once the system has been programmed, the Master key transponder is strictly matched with the control
unit. With this link established, it is now possible to encode new service keys, in the event of losses,
replacements, etc. Each new programming deletes the previous one; to add or delete a key it is therefore
necessary to repeat the procedure using all the keys that you intend to keep in use. If a service key
becomes uncoded, the efficiency of the high voltage circuit shielding must be thoroughly inspected: In
any case it is advisable to use resistive spark plugs.

Diagnostic codes

The Immobilizer system is tested each time the

key switch is turned from «OFF» to «ON». During
this diagnosis phase a number of control unit sta-
tuses can be identified and various light codes
displayed. Regardless of the code transmitted, if
at the end of the diagnosis the LED remains off
permanently, the ignition is enabled. If, however,
the LED remains on permanently, it means the ig-
nition is inhibited:
1. Previously unused control unit - key inser-
ted: a single 2 second flash is displayed, after
which the LED remains off permanently. The keys
can be stored to memory, the vehicle can be star-

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ted but with a limitation imposed on the number of

revs.
2. Previously unused control unit - transpond-
er absent or cannot be used: The LED is per-
manently ON; in this condition, no operations are
possible, including starting of the vehicle.

3. Programmed control unit - the service key in

(normal condition of use): a single 0.7-second
flash is displayed, after which the LED remains off
steadily. The engine can be started.
4. Programmed control unit - Master key in: a
0.7-sec flash is displayed followed by the LED re-
maining off for 2 sec and then by short 0.46-sec
flashes, the same number of times as there are
keys stored in the memory including the Master
key. When the diagnosis has been completed, the
LED remains permanently OFF. The engine can
be started.

5. Programmed control unit - fault detected: a light code is displayed according to the fault detected,
after which the LED remains on steadily. The engine cannot be started. The codes that can be trans-
mitted are:
- 1-flash code
- 2-flash code
- 3-flash code

Diagnostic code - 1 flash

A one-flash code indicates a system where the se-

rial line is not present or is not detected. Check the
Immobilizer aerial wiring and change it if necessa-
ry.

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Diagnostic code - 2 flashes

A two-flash code shows a system where the con-

trol unit does not show the transponder signal. This
might depend on the inefficiency of the immobiliser
aerial or the transponder.
Turn the switch to «ON» using several keys: if the
code is repeated even with the Master key, check
the aerial wiring and change it if necessary. If this
is not the case, replace the defective key and/or
reprogram the control unit.

Diagnostic code - 3 flashes

A three-flash code indicates a system where the

control unit does not recognise the key. Turn the
switch to «ON» using several keys: if the error
code is repeated even with the Master key, replace
the control unit. If this is not the case, reprogram
the decoder.

Ignition circuit

No spark plug
WARNING
ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS
DISCONNECTED.
HV coil primary resistance value:
Disconnect the connector of the HV coil and meas-
ure the resistance between the two terminals.

Characteristic
HV coil resistance primary value:
~ 0.9 Ω

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HV coil secondary resistance value:

1) Disconnect the HV cable from the spark plug
and measure the resistance between the spark
plug cap and the HV coil negative terminal.
2)Disconnect the spark plug cap from the HV cable
and measure the resistance between the HV cable
end and the HV coil negative terminal (see figure).
3) Measure the resistance between the 2 ends of
the spark plug cap.

Characteristic
HV coil secondary resistance value with spark
plug cap
~ 8.4 kΩ
HV coil secondary resistance value:
~ 3.4 kΩ
Spark plug cap resistance value
~ 5 kΩ

Battery recharge circuit

The charging circuit consists of three-phase alternator and a permanent magneto flywheel.
The generator is directly connected to the voltage regulator.
This, in its turn, is connected directly to the ground and the battery positive terminal passing through
the 30A protective fuse.
The three-phase alternator provides good recharge power and at low revs a good compromise is ach-
ieved between generated power and idle stability.

Remote controls check

To check the operation of a solenoid:

1) Check that, given regular conditions, there is no
continuity between terminals 87 and 30.
2) Apply a 12V voltage to power terminals 86 and
85 of the solenoid.
3) With the solenoid fed, check that there is con-
tinuity between terminals 87 and 30.
4) If these conditions are not met, the solenoid is
surely damaged and, therefore, it should be re-
placed.

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Switches check

To check buttons and switches, check that, according to their position, the continuity of contacts is
correct as indicated in the following charts.

KEY
Ar: Orange Az: Sky Blue Bi: White Bl: Blue Gi: Yellow Gr: Grey Ma: Brown Ne: Black Ro: Pink Rs:
Red Ve: Green Vi: Purple

ENGINE STOP SWITCH

STARTER BUTTON

LIGHT SWITCH

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TURN INDICATOR SWITCH

HORN BUTTON

HELMET COMPARTMENT LIGHT SWITCH

SADDLE OPENING SWITCH

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MODE BUTTON

STAND BUTTON

STOP BUTTONS

Stator check

Checking the stator windings

WARNING
THIS CHECK-UP CAN BE MADE WITH THE STATOR PROPERLY INSTALLED.
1) Remove the right side panel.
2) Disconnect the connector between stator and
regulator with the three yellow cables as shown in
the picture.
3) Measure the resistance between each of the
yellow terminals and the other two.
4) Check that there is insulation between the each
yellow cable and the ground.

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Electric characteristic
Resistance:
0.2 - 1 Ω

Voltage regulator check

With a perfectly charged battery and lights off,

measure voltage at the battery poles with a high
running engine.
Voltage should not exceed 15 Volt.
In case higher voltages are detected, replace the
regulator.
In case of voltage values lower than 14 Volt, check
the stator and the corresponding cable harness.

Electric characteristic
Control voltage
14÷15 V to 1500÷12000 rpm

Recharge system voltage check

Look for any leakage

1) Access the battery by removing its cover under the saddle.
2) Check that the battery does not show signs of losing fluid before checking the output voltage.
3) Turn the ignition key to «OFF», connect the multimeter leads between the battery negative pole (-)
and the Black cable. Only then disconnect the Black cable from the battery negative pole (-).
4) With the ignition key always «OFF», the reading indicated by the ammeter must be must be ≤ 0.5
mA.

Charging current check

WARNING
BEFORE CARRYING OUT THE CHECK, MAKE SURE THAT THE BATTERY IS IN GOOD WORK-
ING ORDER.
1) Place the vehicle on its centre stand
2) With the battery correctly connected to the circuit, place the multimeter leads between the battery
terminals..
3) Turn on the engine, increase the engine rpm and, at the same time, measure the voltage.

Electric characteristic
Voltage ranging between 14.0 and 15.0V at 5000 rpm.
Maximum current output check.
- With the engine off and the panel at «ON» with the lights on, allow the battery voltage to stop at 12V.
- Connect ammeter pliers to the 2 recharge positive poles in output from the regulator.

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- Start the engine and rev it up to a high engine speed while reading the value on the pincer.
With an efficient battery a value must be detected: > 20A

VOLTAGE REGULATOR/RECTIFIER
Specification Desc./Quantity
Type Non-adjustable three-phase transistor
Voltage 14 to 15V at 5000 rpm with lights off

Starter motor

KEY
1. Starter motor
2. Starter solenoid
3. Battery
4. Fuse No. 1
5. Ignition key contacts
6. Fuse No. 5
7. Stop buttons
8. Starter button
9. Injection ECU
WARNING
ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS
DISCONNECTED.
1) Check if there is continuity of the Red cable connecting the battery, the start-up solenoid and the
starter motor.

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2) Check fuses No. 1 and 5, the ignition key contacts, the stop light buttons and the starter button.
3) Check the start-up solenoid.
4) If components are in good condition, check that the cable harness connecting them is not interrupted.
5) Check if there is continuity of the Orange-Blue cable between the start-up solenoid and the control
unit connector.

Horn control

KEY
1. Battery
2. Fuse No. 1
3. Ignition key contacts
4. Fuse No. 5
5. Horn button
6. Horn
WARNING
ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS
DISCONNECTED.
1) Check fuses No. 1 and 5, the ignition key contacts and the horn button.
2) If the components are not damaged, check wiring for continuity.
3) Check that the Yellow-Pink cable between the horn and horn button is not interrupted.
4) Check that the Black cable of the horn is grounded.

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Turn signals system check

KEY
1. Battery
2. Fuse No. 1
3. Ignition key contacts
4. Fuse No. 5
5. Turn indicator control device
6. Turn indicator switch
7. LH indicators
8. RH indicators
9. Antitheft
10. Warning light bulb
WARNING
ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS
DISCONNECTED.
1) Check the working order of bulbs.
2) Check fuses No. 1 and 5 and the ignition key contacts.
3) Check if there is intermittent voltage between the Blue-Black cable of the turn indicator control device
and the ground connection.
4) If there is no voltage, check that the cable harness is not interrupted.
5) Check the turn indicator switch.

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6) Check that the Blue-Black cable between the turn indicator control device and the turn indicator switch
is not interrupted.
7) Check that the Pink and White-Blue cables connecting the bulbs and the turn indicator switches are
not interrupted.
8) Check the bulbs ground connection.

level indicators
WARNING
ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS
DISCONNECTED.
If faults are detected:
1) With a multimeter, check resistance values be-
tween the White-Green cable and the Black cable
of the fuel level transmitter by moving the arm with
the float.
2) If the transmitter operates correctly but the in-
dication on the instrument panel is not exact,
check that the cable harnesses between them are
not interrupted.

Electric characteristic
Resistance value when the tank is full
<= 7 Ω
Resistance value when the tank is empty
90 +13/-3 Ω

Lights list

BULBS
Specification Desc./Quantity
1 Low beam light bulb Type: Halogen H7
Quantity: 1
Power: 12V - 55W
2 High beam light bulb Type: Halogen H7
Quantity: 1
Power: 12V - 55W
3 Front tail light bulb Type: LED
Quantity: 1 Right - 1 Left
Power: -
4 Front turn indicator light bulb Type: Spherical BAU 15s
Quantity: 1 Right - 1 Left
Power: 12V - 10W
5 Stop light/rear daylight running light bulb Type: LED
Quantity: 1 Right - 1 Left
Power: -
6 Rear turn indicator light bulb Type: Spherical BAU 15s
Quantity: 1 Right - 1 Left
Power: 12V - 10W

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Specification Desc./Quantity
7 License plate light bulb Type: All glass W5W
Quantity: 1
Power: 12V - 5W
8 Helmet compartment light bulb Type: Cylindrical C5W
Quantity: 1
Power: 12V - 5W
9 Instrument panel lighting bulb Type: LED
Quantity: 4
Power: -

Line for daylight running lights and instrument panel lighting line
In the event of a malfunction, check:
- Efficiency of the bulbs
- Fuses No. 1 and 5
- Ignition key contacts
- Cable harness continuity
High beam/low beam light line
In the event of a malfunction, check:
- Efficiency of the bulbs
- Light switch
- Headlight solenoid
- Fuses No. 1, 4, 5 and 6
- Ignition key contacts
- Cable harness continuity

Fuses

The electrical system is equipped with 6 protection

fuses located below the saddle. Open the saddle
as described above.
Unscrew the three screws «A» and remove the
cover «B»
The chart shows the position and specifications of
the fuses in the vehicle.
CAUTION

BEFORE REPLACING A BLOWN FUSE, FIND AND SOLVE

THE FAILURE THAT CAUSED IT TO BLOW. NEVER TRY
TO REPLACE THE FUSE WITH ANY OTHER MATERIAL
(E.G., A PIECE OF ELECTRIC WIRE).
CAUTION

MODIFICATIONS OR REPAIRS TO THE ELECTRICAL SYS-

TEM, PERFORMED INCORRECTLY OR WITHOUT STRICT
ATTENTION TO THE TECHNICAL SPECIFICATIONS OF

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THE SYSTEM CAN CAUSE MALFUNCTIONING AND RISK

OF FIRE.

FUSES
Specification Desc./Quantity
1 Fuse No. 1 Capacity:30 A
Protected circuits: general, recharge battery
Live: fuses No. 5 and 6
2 Fuse No. 2 Capacity: 15A
Protected circuits: battery-powered: antitheft device
pre-installation, saddle opening control unit pre-installa-
tion, electric fan relay (contact)
3 Fuse No. 3 Capacity: 10A
Protected circuits: battery powered B.T. socket, helmet
compartment light bulb, electronic control unit, injection
load relay (contact); live saddle opener actuator
4 Fuse No. 4 Capacity: 15 A
Protected circuits: battery powered headlight relay
(contact), instrument panel
5 Fuse No. 5 Capacity: 10 A
Protected circuits: live antitheft pre-installation, saddle
opening control unit pre-installation, turn indicator con-
trol device, high-beam flash, instrument panel, daylight
running light, horn, stop lights, starter enabling switch,
licence plate light
6 Fuse No. 6 Capacity: 5A
Protected circuits: live headlight relay (coil), immobil-
iser aerial, electronic control unit, injection load relay
(coil)

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Dashboard

A= High beam warning light

B = Turn indicator warning lights
C = Fuel gauge
D = Low fuel warning light
E = Speedometer
F = Immobiliser LED
G = Coolant temperature gauge
H = Engine control telltale light
I = Engine oil pressure warning light
L = Digital display

Sealed battery
If the vehicle is provided with a sealed battery, the only maintenance required is the check of its charge
and recharging, if necessary.
These operations should be carried out before delivering the vehicle, and on a six-month basis while
the vehicle is stored in open circuit.
Besides upon pre-delivery it is therefore necessary to check the battery charge and recharge it, if re-
quired, before storing the vehicle and afterwards every six months.
INSTRUCTIONS FOR THE RENEWAL RECHARGE AFTER OPEN-CIRCUIT STORAGE
1) Voltage check up

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Before installing the battery on the vehicle, check the open circuit voltage with a standard tester.
- If voltage exceeds 12.60 V, the battery can be installed without any renewal recharge.
- If voltage is below 12.60 V, a renewal recharge is required as explained in 2).
2) Constant voltage battery charge mode
- Constant voltage charge equal to 14.40 to 14.70V
- Initial charge voltage equal to 0.3 to 0.5 for Nominal capacity
- Charge time:
10 to 12 h recommended
Minimum 6 h
Maximum 24 h
3) Constant current battery charge mode
- Charge current equal to 1/10 of the battery rated capacity
- Charge time: Maximum 5 h

Battery installation

VRLA battery (valve-regulated lead-acid battery) Maintenance Free (MF)

WARNING
BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SUL-
PHURIC ACID. AVOID CONTACT WITH YOUR EYES, SKIN AND CLOTHING. IF COMING INTO
CONTACT WITH EYES OR SKIN, WASH ABUNDANTLY WITH WATER FOR APPROX. 15 MIN.
AND SEEK IMMEDIATE MEDICAL ATTENTION.
IN THE EVENT OF ACCIDENTAL INGESTION OF THE LIQUID, IMMEDIATELY DRINK LARGE
QUANTITIES OF WATER OR MILK, MAGNESIUM MILK, BATTERED EGG OR VEGETABLE OIL.
SEEK IMMEDIATE MEDICAL ATTENTION.
BATTERIES PRODUCE EXPLOSIVE GASES; KEEP CLEAR OF NAKED FLAMES, SPARKS OR
CIGARETTES; VENTILATE THE AREA WHEN RECHARGING INDOORS.
ALWAYS WEAR EYE PROTECTION WHEN WORKING IN THE PROXIMITY OF BATTERIES.
KEEP OUT OF REACH OF CHILDREN
1) Battery preparation
Position the battery on a flat surface. Remove the
adhesive sheet closing cells and proceed as quick-
ly as possible to run the subsequent activation
phases.

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2) Electrolyte preparation.
Remove the container of the electrolyte from the
pack. Remove and preserve cover strips from the
container, in fact, the strip will later be used as a
closing cover.
Note: Do not pierce the sealing of the container or
the container itself because inside there is sulphu-
ric acid.

3) Procedure for filling the battery with acid.

Position the electrolyte container upside down with
the six areas sealed in line with the six battery filler
holes. Push the container down with enough force
to break the seals. The electrolyte should start to
flow inside the battery.
Note: Do not tilt the container to prevent the flow
of electrolyte from pausing or stopping.

4) Control the flow of electrolyte

Make sure air bubbles are rising from all six filling holes. Leave the container in this position for 20
minutes or more.
Note:If there are no air bubbles coming out of the filling holes, lightly tap the bottom of the container
two or three times. Do not remove the container from the battery.
5) Take out the container.
Make sure all the electrolyte in the battery is drained. Gently tap the bottom of the container if electrolyte
remains in the container. Now, gently pull the container out from the battery, only do this when the
container is completely empty, and proceed immediately to the next point.
6) Battery closing.
Insert the airtight cover strips into the filling holes. Press horizontally with both hands and make sure
that the strip is levelled with the top part of the battery.
Note:To do this, do not use sharp objects that could damage the closing strip, use gloves to protect
your hands and do not bring your face close to the battery.
The filling process is now complete.
Do not remove the strip of caps under any circumstances, do not add water or electrolyte.
Place the battery down for 1 to 2 hours prior to the charging from the battery.

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7) Recharging the new battery

With the above-mentioned procedure, the battery
will have gained around 70% - 75% of its total
electrical capacity. Before installing the battery on
the vehicle, it must be fully charged and then must
be recharged.
If the battery is to be installed on the vehicle
prior to this pre-charged one, the battery will
not be able to exceed 75% charge without jeop-
ardising its useful life on vehicle.
The dry charge battery MF like the completely loa-
ded YTX, must have a no-load voltage between
12.8 - 13.15 V Bring the battery to full charge, us-
ing the 020648Y battery charger:
a - select the type of battery with the red switch on
the left of the panel battery charger panel
b - select NEW on the yellow timer
c - connect the clamps of the battery charger to the
battery poles (black clamp to negative pole (-) and
red clamp to positive pole (+)).

d - Press the red button, as shown in figure.

e - Press the "MF" black button to activate the bat-

tery recharge Maintenance Free as shown in fig-
ure.

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Electrical system Beverly 300 i.e.

f - Check the ignition of the green LED indicated

with a red arrow in figure.

g - The activation cycle of the new battery lasts for

30 minutes after the ignition of the recharge LED
has taken place

h - Disconnect the clamps from the battery and

check the voltage, if voltages are detected of less
than 12.8 V, proceed with a new recharge of the
battery starting from point c of the recharge pro-
cedure of the new battery, otherwise go to point i

i - The battery is now completely activated, disconnect the battery charger from the fuel supply grid,
disconnect the clamps from the battery and proceed to fitting the battery on the vehicle.

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Connectors

INSTRUMENT PANEL CONNECTOR «A»

1. Left turn indicator warning light (Pink)
2. Immobilizer (Red-Green)
3. Battery-powered (Red-Black)
4. Coolant temperature sensor (Green-Yellow)
5. Not connected
6. Fuel level transmitter (White-Green)
7. Right turn indicator warning light (White-Blue)
8. Low fuel warning light (Grey-Black)

INSTRUMENT PANEL CONNECTOR «B»

1. High-beam warning light (Violet)
2. Ground lead (Black)
3. Injection warning light (Brown-Black)
4. Oil pressure sensor (Pink-White)
5. Live power supply (White)
6. Instrument panel lighting (Yellow-Black)

IMMOBILIZER AERIAL CONNECTOR

1. Live power supply (Red-White)
2. Ground lead (Black)
3. Injection ECU (Orange-White)

FUEL PUMP CONNECTOR

1. Not connected
2. Ground lead (Black)
3. Not connected
4. Not connected
5. Power from solenoid (Black-Green)

ELE SYS - 97
Electrical system Beverly 300 i.e.

ELECTRIC FAN CONNECTOR

1. Ground lead (Black)
2.Power from solenoid (Red)

PICKUP CONNECTOR
1.Engine speed sensor ECU positive (Red)
2.Engine speed sensor ECU negative (Brown)
3. Oil pressure sensor (White-Pink)

ANTITHEFT DEVICE PRE-INSTALLATION

CONNECTOR
1. Left turn indicator bulbs (Pink)
2. Right turn indicator bulbs (White-Blue)
3. Ground lead (Black)
4. Battery-powered (Blue)
5. Live power supply (White)
6. Helmet compartment light (Red-Yellow)
7. Not connected
8. Not connected

2-PIN CONNECTOR ONLY

1 Sky blue-black positive from control unit
2 White-Green negative from control unit

VOLTAGE REGULATOR CONNECTOR

1. Battery positive (Red-Black)
2. Ground lead (Black)
3. Battery positive (Red-Black)
4. Ground lead (Black)

ELE SYS - 98
Beverly 300 i.e. Electrical system

INJECTION ELECTRONIC CONTROL UNIT

CONNECTOR
1. Injection warning light (Brown-Black)
2. Not connected
3. Not connected
4. Lambda probe negative (White-Green)
5. Live power supply (Red-White)
6. Battery-powered (Orange-Black)
7. Immobilizer aerial (Orange-White)
8. Electric fan solenoid (Blue-Yellow)
9. Coolant temperature sensor (Sky blue-Green)
10. Not connected
11. Lambda probe positive (Sky blue-Black)
12. Engine stop switch (Green-Black)
13. Engine speed sensor positive (Red)
14. Injector negative (Yellow-Red)
15. Engine speed sensor negative (Brown)
16. Diagnostics socket (Purple-White)
17. Immobilizer LED (Red-Green)
18. Side stand (Sky blue)
19. Not connected
20. Injection load solenoid (Black-Purple)
21. Not connected
22. HV coil negative (Pink-Black)
23. Not connected
24. Start-up solenoid (Orange-Blue)
25. Fall sensor
26. Ground lead (Black)

INJECTOR CONNECTOR
1. Power from solenoid (Black-Green)
2. Negative from control unit (Yellow-Red)

ELE SYS - 99
Electrical system Beverly 300 i.e.

HV COIL CONNECTOR
1. Negative from control unit (Red-Black)
2. Power from solenoid (Black-Green)

FUEL LEVEL TRANSMITTER CONNECTOR

1. Low fuel warning light (Grey-Black)
2. Ground lead (Black)
3. Fuel level indicator (White-Green)

COOLANT TEMPERATURE SENSOR CON-

NECTOR
1. Ground lead (Grey-Green)
2.Instrument panel (Green-Yellow)
3. Injection ECU (Sky blue-Green)
4. Ground lead (Black)

ELE SYS - 100

INDEX OF TOPICS

ENGINE FROM VEHICLE ENG VE

Engine from vehicle Beverly 300 i.e.

Questa sezione descrive le operazioni da effettuare per lo smontaggio del motore dal veicolo.

Exhaust assy. Removal

- Remove the RH footrest.

- Remove the Lambda probe from its support and
disconnect it.
- Cut the fastening clamp on the lambda probe ca-
ble.

- Undo the two exhaust manifold fixings on the

head. To unscrew the nuts that fix the silencer
flange to the head properly, use a jointed wrench
that allows, according to the travel direction, to get
also at the right nut. That is difficult to do with a
traditional straight wrench.

- Unscrew the three screws fastening the heat

shield to the silencer;
- Unscrew the three screws «A» fastening the si-
lencer to the silencer mounting bracket.
- Remove the full silencer unit.

ENG VE - 102
Beverly 300 i.e. Engine from vehicle

Remove the lambda probe from the manifold.

Removal of the engine from the vehicle

CAUTION

SUPPORT THE VEHICLE ADEQUATELY.

Disconnect the battery.
- Remove the side fairings.
- Remove the inspection cover in helmet compart-
ment.
- Remove the full silencer unit.
- Remove the air filter.
- Release the blow-by return pipe from the clamp
and disconnect it from the head.
CAUTION

THIS OPERATION MUST BE CARRIED OUT WHEN THE

ENGINE IS COLD.

ENG VE - 103
Engine from vehicle Beverly 300 i.e.

- Unscrew the screw indicated in the figure and re-

lease the rear brake hose from the silencer mount-
ing bracket;

- Unscrew the two bolts fastening the rear brake

calliper to the silencer mounting bracket;

- Working on the vehicle right side, remove the

coolant intake pipes and empty the system.
N.B.
LET THE COOLANT DRAIN INTO A CONTAINER OF ADE-
QUATE CAPACITY.

Characteristic
Cooling system fluid
~2l

- Disconnect:
- fuel piping and retainer clamp.
- injector connector.
- control unit connector.

ENG VE - 104
Beverly 300 i.e. Engine from vehicle

- Remove the coolant outlet pipe from the engine

as indicated.

- Remove the spark plug cap.

- Remove the coolant temperature sensor con-
nector indicated in the picture.

- Remove the throttle cables from the throttle body

by undoing the nuts indicated in the picture.

- Remove the positive and negative wiring from the

starter motor as shown in the picture.

ENG VE - 105
Engine from vehicle Beverly 300 i.e.

- Release the cable harness from the cable grom-

met clamp and remove the clamp indicated.
- Disconnect the oil minimum pressure sensor.

- Remove the lower screws of the right and left

shock absorber.

- Take out the ground retainer on the engine.

ENG VE - 106
Beverly 300 i.e. Engine from vehicle

- Remove the pin fixing the engine to the swinging

arm.
- The engine is now free.

Upon refitting the engine to the vehicle, carry out

the removal operations but in reverse order, and
respect the tightening torque shown in the «Spec-
ifications» Chapter.
- Check that there is a small clearance when the
valve is in abutment against the set screw.
- Check the engine oil level and if necessary, top
it up with the recommended type.
- Fill and bleed the cooling circuit.
- Check accelerator and electric devices for correct
functioning.
- Pay particular attention to the sleeve, be careful
to position the throttle body reference marks as in-
dicated in the picture.
CAUTION
PAY PARTICULAR ATTENTION TO POSITIONING THE
THROTTLE CONTROL TRANSMISSION PROPERLY.

ENG VE - 107
INDEX OF TOPICS

ENGINE ENG
Beverly 300 i.e. Engine

This section describes the operations to be carried out on the engine and the tools to be used.

This section describes the operations to be carried out on the engine and the tools to be used.

This section describes the operations to be carried out on the engine and the tools to be used.

Automatic transmission

Transmission cover

- Remove the air duct.

- With the specific tool lock the driven pulley, undo
the indicated nut and collect the washer.

Specific tooling
020423Y Driven pulley lock wrench

- Undo the eleven fixings screws to the engine and

remove the transmission cover
N.B.
WHEN YOU ARE REMOVING THE TRANSMISSION COVER
YOU MUST BE CAREFUL NOT TO DROP THE CLUTCH
HOUSING.

Air duct

- Undo the three screws «1» and remove the

crankcase cover «2».

ENG - 109
Engine Beverly 300 i.e.

- Undo the three screws «3» and remove the filter

cover in the transmission housing «4».

- Take out the filtering element «5» from the cover.

Removing the driven pulley shaft bearing

- Remove the clip from the inside of the cover.

- Remove the bearing from the crankcase by
means of:

Specific tooling
020376Y Adaptor handle
020375Y 28 x 30 mm adaptor
020412Y 15-mm guide

Refitting the driven pulley shaft bearing

- Heat the crankcase from the inside.

- Insert the bearing in its seat.
- Refit the Seeger ring.
CAUTION
USE AN APPROPRIATE SUPPORT TO AVOID DAMAGING
THE COVER SURFACE.
N.B.
ALWAYS REPLACE THE BEARING WITH A NEW ONE
UPON REFITTING.

Specific tooling
020376Y Adaptor handle
020357Y 32x35-mm Adaptor

ENG - 110
Beverly 300 i.e. Engine

020412Y 15-mm guide

Removing the driven pulley

- Remove the stationary driving half-pulley and the

clutch housing.
- Remove the driven pulley together with the belt.

Inspecting the clutch drum

- Check that the clutch bell is not worn or damaged.

- Measure the clutch bell inside diameter.

Characteristic
Max. value clutch bell
Max. value: Ø 134.5 mm
clutch housing standard value
Standard value: Ø 134 - 134.2 mm

Checking the bell working surface eccentricity

- Install the bell on a driven pulley shaft using 2
bearings (inside diameter: 15 and 17 mm).
- Lock with the original spacer and nut.
- Place the bell/shaft unit on the support to check
the crankshaft alignment.

ENG - 111
Engine Beverly 300 i.e.

- Using a feeler dial gauge and the magnetic base,

measure the bell eccentricity.
- Repeat the measurement in 3 positions (Central,
internal, external).
- If faults are found, replace the bell.

Specific tooling
020074Y Support base for checking crankshaft
alignment
020335Y Magnetic mounting for dial gauge

Characteristic
clutch bell inspection: Limit eccentricity.
Admissible limit eccentricity: 0.15 mm

Removing the clutch

Fit the driven pulley spring compressor specific

tool with medium length pins screwed in position
«C» on the tool internal side.
- Introduce the adapter ring 11 with the chamfering
facing the inside of the tool.
- Fit the driven pulley unit on the tool with the in-
sertion of the 3 pins in the ventilation holes in the
mass holder support.
- Make sure that the clutch is perfectly inserted into
the adapter ring before proceeding to loosen/tight-
en the clutch nut.
- Use the special 46x55 wrench component 9 to
remove the nut fixing the clutch in place.
- Dismantle the driven pulley components (Clutch
and spring with its plastic holder)
CAUTION
THE TOOL MUST BE FIRMLY FIXED IN THE CLAMP AND
THE CENTRAL SCREW MUST BE BROUGHT INTO CON-
TACT WITH THE TOOL. EXCESSIVE TORQUE CAN CAUSE
THE SPECIFIC TOOL TO BUCKLE.

Specific tooling
020444Y011 adapter ring
020444Y009 wrench 46 x 55
020444Y Tool for fitting/ removing the driven
pulley clutch

ENG - 112
Beverly 300 i.e. Engine

Inspecting the clutch

- Check the thickness of the clutch mass friction

material.
- The masses must not show traces of lubricants;
otherwise, check the driven pulley unit seals.
N.B.
UPON RUNNING-IN, THE MASSES MUST EXHIBIT A CEN-
TRAL FAYING SURFACE AND MUST NOT BE DIFFERENT
FROM ONE ANOTHER.
VARIOUS CONDITIONS CAN CAUSE THE CLUTCH TO
TEAR.
CAUTION
DO NOT OPEN THE MASSES USING TOOLS TO PREVENT
A VARIATION IN THE RETURN SPRING LOAD.

Characteristic
Check minimum thickness
1 mm

Pin retaining collar

- Simultaneously turn and pull the collar manually

to remove it.
N.B.
USE TWO SCREWDRIVERS IF YOU HAVE ANY DIFFICUL-
TY.
N.B.
BE CAREFUL NOT TO PUSH THE SCREWDRIVERS IN TOO
FAR TO AVOID DAMAGE THAT COULD COMPROMISE
THE O-RING SEAL.

- Remove the 4 torque server pins and pull the

pulley halves apart.

ENG - 113
Engine Beverly 300 i.e.

Removing the driven half-pulley bearing

- Check there are no signs of wear and/or noisi-

ness; - Replace with a new one if there are.
- Remove the retainer ring using two flat blade
screwdrivers.
- Support the pulley bushing adequately from the
threaded side using a wooden surface.
- Using a hammer and pin, knock the ball bearing
out as shown in the figure.

- Support the pulley properly using the bell as

shown in the figure.

Specific tooling
001467Y035 Bearing housing, out ø 47 mm

- Remove the roller bearing using the modular punch.

Specific tooling
020376Y Adaptor handle
020456Y Ø 24 mm adaptor
020363Y 20-mm guide

Inspecting the driven fixed half-pulley

Version 250
- Measure the outside diameter of the pulley bush-
ing.
- Check the faying surface with the belt to make
sure there are no flaws.
- Check the riveted joints are functional.
- Check the evenness of the belt contact surface.

Characteristic
Half-pulley minimum diameter
Minimum admissible diameter: Ø 40.96 mm

ENG - 114
Beverly 300 i.e. Engine

Half-pulley standard diameter

Standard diameter: Ø 40.985 mm
Wear limit
0.3 mm

Inspecting the driven sliding half-pulley

- Remove the two seal rings and the two O-rings.

- Measure the movable half-pulley bushing inside
diameter.
- Check the faying surface with the belt to make
sure there are no flaws.
- Check the riveted joints are functional.
- Check the evenness of the belt contact surface.

MOVABLE DRIVEN HALF-PULLEY DIMENSIONS

Specification Desc./Quantity
Wear limit 0.3 mm
standard diameter Ø 41.000 - 41.035 mm
maximum allowable diameter Ø 41.08 mm

ENG - 115
Engine Beverly 300 i.e.

Refitting the driven half-pulley bearing

- Support the pulley bushing adequately from the

threaded side using a wooden surface.
- Fit a new roller bearing as shown in the figure.
- For the fitting of the new ball bearing, follow the
example in the figure using a modular punch.
Fit the retainer ring
WARNING
N.B.
FIT THE BALL BEARING WITH THE VISIBLE SHIELDING

Specific tooling
020376Y Adaptor handle
020375Y 28 x 30 mm adaptor
020424Y Driven pulley roller casing fitting
punch

Refitting the driven pulley

- Insert the new oil seals and O-rings on the mov-

able half-pulley.
- Lightly grease the O-rings «A» shown in the fig-
ure.
- Fit the half-pulley over the bushing using the spe-
cific tool.
- Check that the pins are not worn and proceed to
refitting them in their slots.
- Refit the torque server closure collar.
- Using a curved-spout grease gun, lubricate the
driven pulley unit with approximately 6 grams of
grease. Apply grease through one of the holes in
the bushing until it comes out through the hole on
the opposite side. This operation is necessary to
avoid the presence of grease beyond the O-rings.
N.B.

ENG - 116
Beverly 300 i.e. Engine

THE TORQUE SERVER CAN BE GREASED WHETHER

WITH BEARINGS FITTED OR WHEN THEY ARE BEING RE-
PLACED; UNDERTAKING THE OPERATION WHEN THE
BEARINGS ARE BEING SERVICED MIGHT BE EASIER.

Specific tooling
020263Y Driven pulley assembly sheath

Recommended products
AGIP GREASE SM 2 Grease for the C-ring of
the tone wheel
Soap-based lithium grease containing NLGI 2 Mo-
lybdenum disulphide; ISO-L-XBCHB2, DIN
KF2K-20

Inspecting the clutch spring

- Measure the length of the spring when it is re-

laxed.

Characteristic
Standard length
145 mm
Acceptable limit after use
140 mm

Refitting the clutch

- Support the driven pulley spring compressor spe-

cific tool with the control screw in vertical axis.
- Arrange the tool with the medium length pins
screwed in position "C" on the inside.
- Introduce the adapter ring No. 11 with the cham-
fering facing upwards.
- Insert the clutch on the adapter ring.
- Lubricate the end of the spring that abuts against
the torque server closing collar.
- Insert the spring with its plastic holder in contact
with the clutch.
- Insert the drive belt into the pulley unit according
to their direction of rotation.
- Insert the pulley unit with the belt into the tool.
- Slightly preload the spring.

ENG - 117
Engine Beverly 300 i.e.

- Make sure that the clutch is perfectly inserted into

the adapter ring before proceeding to tighten the
clutch nut.
- Place the tool in the clamp with the control screw
on the horizontal axis.
- Fully preload the spring.
- Apply the clutch fixing nut and tighten it to the
prescribed torque using the special 46x55 wrench.
- Loosen the tool clamp and insert the belt accord-
ing to its direction of rotation.
- Lock the driven pulley again using the specific
tool.
- Preload the clutch return spring with a traction/
rotation combined action and place the belt in the
smaller diameter rolling position.
- Remove the driven pulley /belt unit from the tool.
N.B.
DURING THE SPRING PRELOADING PHASE, BE CARE-
FUL NOT TO DAMAGE THE PLASTIC SPRING STOP AND
THE BUSHING THREADING.
N.B.
FOR DESIGN REASONS, THE NUT IS SLIGHTLY ASYM-
METRIC; THE FLATTEST SURFACE SHOULD BE MOUN-
TED IN CONTACT WITH THE CLUTCH.

Specific tooling
020444Y Tool for fitting/ removing the driven
pulley clutch
020444Y011 adapter ring
020444Y009 wrench 46 x 55

Locking torques (N*m)

Clutch unit nut on driven pulley 45 to 50

ENG - 118
Beverly 300 i.e. Engine

Refitting the driven pulley

- Fit the clutch housing on the driven pulley paying

attention to the position of the washer indicated.

Drive-belt

- Make sure the drive belt is not damaged and does not show abnormal wear.
- Replace as indicated in the scheduled maintenance table.

Removing the driving pulley

- Turn the crankshaft until the ropes of the pulley

are on a horizontal axis

ENG - 119
Engine Beverly 300 i.e.

- Insert the adaptor sleeve of the appropriate tool

in the hole shown in the picture

- Insert the tool in the hollows and apply the reten-

tion ring
- Bring in the ring's clamping screws while keeping
the tool to support the pulley
- Remove the fixing nut and the washer
- Remove the stationary drive pulley half.

Specific tooling
020626Y008 Driving pulley lock wrench
- Remove nut «1», Belleville spring «2», and wash-
er «3».

- Remove the stationary driving half-pulley.

ENG - 120
Beverly 300 i.e. Engine

- Detach the drive belt from the crankshaft, remove

the sliding bushing and the entire roller housing.

Inspecting the rollers case

- Check that the internal bushing shown in the fig-

ure is not abnormally worn and measure inner
diameter A.
- Measure outer diameter B of the pulley sliding
bushing shown in the figure.
- Check that the rollers are not damaged or worn.
- Check the guide shoes for the variator back-plate
are not worn.
- Check the wear of the roller housings and of the
belt faying surfaces on both pulley halves.
- Check that stationary driving pulley does not
show signs of abnormal wear on the grooved edge
and on the surface in contact with the belt.
- Check that the O-ring is not pushed out of shape.
CAUTION
DO NOT LUBRICATE OR CLEAN SINTERED BUSHINGS

Characteristic
movable driving half-pulley bushing: Standard
Diameter
26.000 - 26.021 mm
movable driving half-pulley bushing: Maxi-
mum allowable diameter
Ø 26.12 mm
Sliding bushing: Standard Diameter
Ø 25.959 ÷ 25.98 mm
Sliding bushing: Minimum admissible diame-
ter
Ø 25.95 mm
Roller: Standard diameter

ENG - 121
Engine Beverly 300 i.e.

Ø 19.5 - 20.1 mm
Roller: Minimum admissible weight
5.4 ± 0.15 g

Refitting the driving pulley

- Preassemble the movable half-pulley with the

roller contrast plate by putting the rollers in their
housings with the larger support surface touching
the pulley according to the direction of rotation.
- Check that the roller contact plate does not have
flaws and is not damaged on the grooved edge.
- Mount the complete bushing unit on the crank-
shaft.
- Fit the driven pulley/Clutch/belt unit on the en-
gine.

ENG - 122
Beverly 300 i.e. Engine

- Fit the steel shim in contact with the bushing and

the stationary drive pulley.
- Install the appropriate tool as described in the re-
moval phase.
-Tighten the nut with washer to the prescribed tor-
que.

Specific tooling
020626Y008 Driving pulley lock wrench

Locking torques (N*m)

Drive pulley nut 75 - 83

Refitting the transmission cover

- Check that there are two alignment dowels and

that the sealing gasket for the oil sump on the
transmission cover is adequately fitted.
- Refit the cover and tighten the «12» screws to the
specified torque.
- Refit the steel washer and the driven pulley nut.
- Tighten the nut to the prescribed torque using the
lock wrench and the torque wrench tools.
- Refit the plastic cover.

Specific tooling
020423Y Driven pulley lock wrench

Locking torques (N*m)

Transmission cover screws 11 to 13 Driven pul-
ley shaft nut 54 ÷ 60

End gear

ENG - 123
Engine Beverly 300 i.e.

Removing the hub cover

- Empty the reduction oil through the drain screw

«1».
- Undo the six screws «2», and the screw «3».

- Remove gasket «4» and make sure that align-

ment dowels «5» are adequately positioned.

Removing the wheel axle

- Remove the wheel axis complete with gear.

- Remove the intermediate gear.

ENG - 124
Beverly 300 i.e. Engine

Removing the hub bearings

- Check the state of the bearings being examined

(wear, clearance and noisiness). If faults are de-
tected, do the following.
- Use the specific bearing extractor to remove the
three 15 mm bearings (2 in the crankcase and 1 in
the hub cover).

Specific tooling
001467Y013 Calliper to extract ø 15-mm bear-
ings

Removing the wheel axle bearings

- Take out the clip on the outside of the hub cover.

- Support the hub cover and expel the bearing.
By means of the appropriate tools, remove the oil
guard as in the figure.

Specific tooling
020376Y Adaptor handle
020477Y 37 mm adaptor
020483Y 30-mm guide
020359Y 42x47-mm Adaptor
020489Y Hub cover support stud bolt kit

ENG - 125
Engine Beverly 300 i.e.

Removing the driven pulley shaft bearing

- Extract the driven pulley shaft from its bearing.

- Remove the oil seal using a screwdriver and be
careful not to damage the seat.

- Remove the Seeger ring indicated.

Specific tooling
020376Y Adaptor handle
020375Y 28 x 30 mm adaptor
020363Y 20-mm guide

- Remove the driven pulley shaft bearing using the

modular punch.

Specific tooling
020376Y Adaptor handle
020375Y 28 x 30 mm adaptor
020363Y 20-mm guide

Inspecting the hub shaft

- Check that the 3 shafts exhibit no wear or defor-

mation on the grooved surfaces, at the bearings
and at the oil seals.
- In case of faults, replace the damaged parts.

ENG - 126
Beverly 300 i.e. Engine

Characteristic
Connection diameter for countershaft:
A = Ø 15 - 0.01 -0.02 mm
Connection diameter for wheel shaft:
B = Ø 25 - 0.020 -0.035 mm
C = diameter 15 - 0.01 -0.02 mm
Bearing diameter for driven pulley shaft:
D = Ø 15 - 0.01 -0.02 mm
E = 19.8 ± 0.1
F = Ø 20 - 0.01 -0.02 mm

Inspecting the hub cover

- Check that the fitting surface is not dented or distorted.

- Check the bearing bearings.
- In case of faults, replace the damaged components.

ENG - 127
Engine Beverly 300 i.e.

Refitting the wheel axle bearing

- Support the hub cover on a wooden surface.

- Heat the crankcase cover with the specific heat
gun.
- Fit the wheel shaft bearing with a modular punch
as shown in the figure.
- Fit the Seeger ring.
- Fit the oil guard with seal lip towards the inside
of the hub and place it flush with the internal sur-
face by means of the appropriate tool used from
the 52-mm side.
The 52-mm side of the adapter must be turned to-
wards the bearing.

Specific tooling
020376Y Adaptor handle
020360Y 52x55-mm Adaptor
020483Y 30-mm guide

ENG - 128
Beverly 300 i.e. Engine

Refitting the hub cover bearings

In order to fit the hub box bearings, the engine

crankcase and the cover must be heated with the
special heat gun.
- The three 15-mm bearings must be fitted using
the appropriate tools:
- The 42-mm side of the adapter must be turned
towards the bearing.

Specific tooling
020150Y Air heater mounting
020151Y Air heater
020376Y Adaptor handle
020359Y 42x47-mm Adaptor
020412Y 15-mm guide

N.B.
TO FIT THE BEARING ON THE COVER, ADEQUATELY SUPPORT THE COVER WITH THE STUD
BOLT KIT.
- Refit the driven pulley shaft bearing with a mod-
ular punch as shown in the figure.
N.B.
IF THE BEARING HAS AN ASYMMETRICAL BALL RETAIN-
ER, PLACE IT SO THAT THE BALLS ARE VISIBLE FROM
THE HUB INNER SIDE.

Specific tooling
020376Y Adaptor handle
020359Y 42x47-mm Adaptor
020363Y 20-mm guide
N.B.
WHEN FITTING THE BEARINGS ON THE ENGINE CRANKCASE, SUPPORT THE CRANKCASE
PREFERABLY ON A SURFACE TO ALLOW THE BEARINGS TO BE DRIVEN VERTICALLY.
- Refit the Seeger ring with the opening facing the bearing and fit a new oil seal flush with the crankcase
from the pulley side.

ENG - 129
Engine Beverly 300 i.e.

Refitting the hub bearings

- Install the three shafts in the engine crankcase

as shown in the figure.

Refitting the ub cover

- Fit a new gasket together with the alignment

dowels.
- Seal the gasket of the breather pipe using black
silicone sealant.
- Fit the gearbox cover, making sure the breather
pipe is in the correct position.
- Position the shorter screw that can also be rec-
ognised from the different colour as shown in the
figure.
- Fix the breather tube support by means of the
lower screw.
- Fit the remaining screws and tighten the seven
screws to the prescribed torque.

Locking torques (N*m)

Hub cover fixing screws 24 to 27 Hub oil drain
screws 15 to 17

Flywheel cover

ENG - 130
Beverly 300 i.e. Engine

Removing the hub cover

- Remove the clamps fastening the water pipes on

the pump cover.
- Detach the pipes from the pump cover.

- Unscrew the ten screws fastening the flywheel,

retrieving the indicated plate.
- Disconnect the electric connector from the mini-
mum oil pressure switch.

- Remove the flywheel cover.

- Remove the gasket and be careful with the two

alignment dowels.

ENG - 131
Engine Beverly 300 i.e.

Removing the stator

- Remove the two pickup screws and the screw

holding the wiring support and the three stator
clamping screws shown in the figure.
- Remove the stator and its wiring.

Refitting the stator

- Refit the stator and flywheel carrying out the re-

moval procedure in reverse, tightening the retain-
ers to the specified torque.

Locking torques (N*m)

Stator fixing screws 8 to 10 Pickup fixing
screws 3 to 4

Refitting the flywheel cover

- Fit the gasket and be careful with the two align-

ment dowels.

ENG - 132
Beverly 300 i.e. Engine

- Position the spline clip on the crankshaft and ori-

ent the end as shown in the figure.

- Orient the water pump shaft with reference to the

transmission gear seat as shown in the picture.

- Fit the flywheel cover complete with pump, en-

suring that the alternator cable grommet is fitted
correctly.
- Tighten the ten screws fastening the flywheel
cover, ensuring that the indicated plate is posi-
tioned correctly.
- Reconnect the electric connector on the mini-
mum oil pressure switch.

- Fit the water pipes onto the unions on the pump

cover and tighten the clamps.

Locking torques (N*m)

Flywheel cover screw 11 to 13

Flywheel and starting

ENG - 133
Engine Beverly 300 i.e.

Removing the starter motor

- Remove the two screws indicated in the figure

- Take the starter motor out of its seat

Removing the flywheel magneto

- Remove the screw and the plate of the starting

sprocket.

- Fit the specific tool, screw the guide bushing to

the flywheel, insert the flywheel stop tool as shown
in the picture.

Specific tooling
020627Y Flywheel lock wrench

- Undo the flywheel screw and remove the washer.

- Manually screw the nut without washer, being
careful not to leave the first threads uncovered.
CAUTION

SCREWING UP THE NUT WITHOUT WASHER HELPS PRO-

TECT THE THREAD AGAINST THE STRAIN EXERTED BY
THE EXTRACTOR AND ALSO PREVENTS DROPPING THE
FLYWHEEL ACCIDENTALLY UPON EXTRACTING IT. PO-
TENTIAL DROPS MAY DAMAGE THE CERAMIC INSERTS.

ENG - 134
Beverly 300 i.e. Engine

- Insert the extractor.

Specific tooling
020467Y Flywheel extractor

- Act on the extractor to remove the flywheel to-

gether with the starting sprocket.

Inspecting the flywheel components

- Check the integrity of the internal plastic parts of the flywheel and the Pick-up control plate.

Starter gear rim

See also
Removing the flywheel magneto

ENG - 135
Engine Beverly 300 i.e.

Intermediate gear

- Remove the flywheel cover.

- Remove the intermediate gear and take it out of
its housing.

Refitting the free wheel

- Make sure the freewheel faying surfaces are in good condition.

- Thoroughly clean the free wheel to remove LOCTITE residue.
- Degrease the threading of the holes in the free wheel and the clamping screws.
- Apply the recommended product to the end of the screws.

Recommended products
Loctite 243 Medium strength threadlock
Medium Loctite 243 threadlock

- Fit the freewheel on the magneto flywheel making

sure that the ground side is in contact with the fly-
wheel itself, i.e. with wheel Seeger ring visible.
- Lock the six clamping screws in criss-cross fash-
ion to the prescribed torque.

Locking torques (N*m)

Screw fixing freewheel to flywheel 13 - 15

- Oil the free wheel "rollers".

ENG - 136
Beverly 300 i.e. Engine

Refitting the flywheel magneto

- Remove the freewheel retaining plate indicated

in the picture
- Remove the transmission gear and the freewheel

- Insert the free wheel on the flywheel as shown in

the picture
- Then refit the flywheel with free wheel and trans-
mission gear

- Using the special flywheel lock wrench, tighten

up the flywheel fixing nut to the prescribed torque
- Refit the retention plate

Specific tooling
020627Y Flywheel lock wrench

Locking torques (N*m)

Flywheel nut 94 - 102

Refitting the starter motor

- Fit a new O-ring on the starter motor and lubricate

it.
- Fit the starter motor on the crankcase and lock
the 2 screws to the prescribed torque.

Locking torques (N*m)

Starter screws 11 to 13

ENG - 137
Engine Beverly 300 i.e.

Cylinder assy. and timing system

Removing the intake manifold

- Undo the three screws with an anti-tampering

device.

Removing the rocker-arms cover

- Remove the five screws shown in the figure.

- Remove the entire head cover.

Removing the timing system drive

- Remove the oil pump control gear and the pinion

separation washer as described in the «Engine/
Lubrication/Oil pump» section.
- Undo the central screw and collect the washer.
Undo the two fixing screws to the cylinder and re-
move the tensioner together with the gasket.

ENG - 138
Beverly 300 i.e. Engine

- Undo the two screws indicated.

- Detach the timing chain and remove the camshaft

control pulley and the corresponding washer.

- Remove the screws indicated in the figure, the

spacer bar and the tensioner slider.
- Remove the control sprocket wheel and the tim-
ing chain.
- As regards the chain guide slider, it may only be
removed after the head has been removed.
N.B.
IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO EN-
SURE THAT THE INITIAL DIRECTION OF ROTATION IS
MAINTAINED.

Removing the cam shaft

- Undo the two indicated fixing screws to the cyl-

inder and remove the fixing plate.

ENG - 139
Engine Beverly 300 i.e.

- Remove the camshaft.

- Acting on flywheel-side holes, push and slide off

the rocking lever pins.
N.B.
IF NEEDED, THE HEAD MAY BE REMOVED WITH THE
CAMSHAFT, ROCKER PINS AND FIXING BRACKET. THE
HEAD CAN ALSO BE REMOVED WITHOUT REMOVING
THE CHAIN AND THE CRANKSHAFT CHAIN TENSIONER.

Removing the cylinder head

- Undo the two screws «1» fixing the head to the

transmission-side crankcase half.
- Unscrew the four nuts «2» by loosening them in
two or three stages and in a crossed sequence.

ENG - 140
Beverly 300 i.e. Engine

- Remove the head.

N.B.
IF NEEDED, THE HEAD MAY BE REMOVED WITH THE
CAMSHAFT, ROCKER PINS AND FIXING BRACKET. THE
HEAD CAN ALSO BE REMOVED WITHOUT REMOVING
THE CHAIN AND THE CRANKSHAFT CHAIN TENSIONER.

- Remove the gasket.

Removing the valves

- Using the appropriate tool fitted with an adaptor,

remove the cotters, caps, springs and valves.
- Remove the oil guards with the appropriate tool.
- Remove the lower spring supports.
CAUTION
REPLACE THE VALVES IN SUCH A WAY AS TO RECOG-
NISE THEIR ORIGINAL POSITION ON THE HEAD.

Specific tooling
020382Y011 adapter for valve removal tool
020382Y Valve cotters equipped with part 012
removal tool
020431Y Valve oil seal extractor

ENG - 141
Engine Beverly 300 i.e.

Removing the cylinder - piston assy.

- Remove the chain guide slider; be careful with

the two alignment dowels and remove the cylinder.

- Remove the base gasket; be careful with the two

centring dowels and the dowel pin.

- Remove the sealing rings, the pin and remove

the piston.
CAUTION
TO PREVENT DAMAGING THE PISTON, SUPPORT IT
WHILE REMOVING THE CYLINDER.
N.B.
BE CAREFUL NOT TO DAMAGE THE SEALING RINGS
DURING REMOVAL.

Inspecting the small end

N.B.
TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP-
TER.
See also
Crankcase - crankshaft - connecting rod

Inspecting the wrist pin

N.B.
TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP-
TER.
See also

ENG - 142
Beverly 300 i.e. Engine

Cylinder - piston assy.

Inspecting the piston

N.B.
TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP-
TER.
See also
Cylinder - piston assy.

Inspecting the piston rings

N.B.
TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP-
TER.
See also
Piston rings

Removing the piston

- Install piston and wrist pin onto the connecting

rod, aligning the piston arrow the arrow facing to-
wards the exhaust.

- Fit the pin retainer ring onto the appropriate tool

- With opening in the position indicated on the tool
S = left
D= right
- Place the wrist pin retainer ring into position using
a punch
- Fit the wrist pin retainer ring using the plug as
shown in the figure
N.B.
THE TOOL FOR INSTALLING THE RETAINER RINGS MUST
BE USED MANUALLY.
CAUTION
USING A HAMMER MIGHT DAMAGE THE STOPS' HOUS-
ING.

Specific tooling
020430Y Pin lock fitting tool

ENG - 143
Engine Beverly 300 i.e.

Choosing the gasket

- Provisionally fit the piston into the cylinder, without any base gasket.
- Install a dial gauge on the special tool using the short union, as shown in the figure.

Specific tooling
020475Y Piston position checking tool

- Using an abutment plane, reset the dial gauge

with a preload of a few millimetres.
- Finally fix the dial gauge.
- Check the perfect sliding of the feeler pin.
- Install the tool on the cylinder without changing
the dial gauge position.
- Lock the tool using the original head fixing nuts.
- Rotate the crankshaft up to the TDC (the inver-
sion point of the dial gauge rotation)
- Measure the deviation from the reset value.

- By means of the table, see the Specifications chapter identify the cylinder base gasket thickness to
be used for refitting. Correctly identify the cylinder base gasket thickness to keep the correct compres-
sion ratio.
- Remove the special tool and the cylinder.
N.B.
IF DEVIATIONS (OR RECESSES OR PROJECTIONS) CLOSE TO THE CHANGE OF CATEGORY
ARE MEASURED, REPEAT THE MEASUREMENT AT THE OPPOSED SIDE. TO DO SO, REPEAT
THE TOOL INSTALLATION BY INVERTING ITS POSITION.

ENG - 144
Beverly 300 i.e. Engine

See also
Slot packing system

Refitting the piston rings

- Pistons (like cylinders) are supplied in 4 catego-

ries: A, B, C and D, and must be fitted so that the
reference arrow faces the exhaust duct. The letter
is found at the centre of the piston.
- Fit the sealing rings with the word TOP or the
identification letter facing upwards. In any case,
the step must be facing opposite the piston crown.
- Sealing rings are manufactured with a cylinder
contact conical cross-section and piston gaps
must be offset by 120° in order to obtain a better
bedding.
- Lubricate rings with engine oil when fitting them.

Refitting the cylinder

N.B.
BEFORE FITTING THE CYLINDER, CAREFULLY BLOW OUT THE LUBRICATION DUCT AND OIL
THE CYLINDER BARREL.

ENG - 145
Engine Beverly 300 i.e.

- Check the position of the centring dowels and

dowel pin and fit a gasket with a thickness previ-
ously determined.

- Using the specific tool fit the cylinder paying at-

tention that the chain does not remain in the timing
system compartment.

Specific tooling
020426Y Piston fitting fork
020393Y Piston assembly band

Inspecting the cylinder head

N.B.
TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP-
TER.
See also
Cylinder Head

Inspecting the timing system components

- Check that the guide slider and the tensioner

slider are not worn out.
- Ensure that the camshaft control pulley chain as-
sembly and the sprocket wheel are not worn.
- If you detect wear, replace the parts or, if the
chain, sprocket wheel and pulley are worn, replace
the whole unit.
- Remove the centre screw with the washer and
the tensioner spring. Check that the one-way
mechanism is not worn.
- Check the condition of the tensioner spring.
- If examples of wear are found, replace the whole
unit.

ENG - 146
Beverly 300 i.e. Engine

Inspecting the valve sealings

N.B.
TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP-
TER.
See also
Cylinder Head

Inspecting the valves

N.B.
TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP-
TER.
See also
Cylinder Head

Inspecting the springs and half-cones

- Check that the upper and lower supporting spring

washers, the cotters and the oil seal show exhibit
no signs of abnormal wear. Replace a component
when worn.

N.B.
TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP-
TER.
See also
Cylinder Head

ENG - 147
Engine Beverly 300 i.e.

Refitting the valves

- Lubricate the valve guides with engine oil.

- Place the valve spring supports on the head.
- Using the special punch, fit the four valve seal
rings.
- Fit the valves, the springs and the caps. Using
the appropriate tool with adapter, compress the
springs and insert the cotters in their seats.
N.B.
DO NOT CHANGE THE VALVE FITTING POSITION. FIT THE
VALVE SPRINGS WITH THE REFERENCE COLOUR ON
COTTER SIDE (TURNS WITH GREATER PITCH).

Specific tooling
020306Y Punch for assembling valve seal
rings
020382Y011 adapter for valve removal tool
020382Y Tool to extract valve cotters

Inspecting the cam shaft

N.B.
TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP-
TER.
See also
Cylinder Head

Refitting the head and timing system components

Assemble the timing chain sprocket wheel on the

crankshaft with the chamfering facing the insertion
side and observing the position of the reference
dowel.

ENG - 148
Beverly 300 i.e. Engine

- Loop the timing control chain «1» around the

crankshaft.
- Fit the guide slider and the tensioner pad «2» on
the head side.
- Fit spacer «5» with fixing screw «6».
- Tighten the screws to the prescribed torque.

Locking torques (N*m)

Slider screw 10 - 14 Nm
- Fit the head gasket and check that the alignment
dowels work properly.
- Insert the head.
- Lubricate the stud bolt threads with engine oil.
- Tighten up the nuts to an initial pre-torque of 7±1
Nm.
- Tighten up the nuts to a second pre-torque of 10
±1 Nm
- To carry out the operations described above, fol-
low the tightening sequence in the figure.
- Fit the two screws on the outside of the timing
chain side and tighten them to the specified torque.
N.B.
BEFORE INSTALLING THE HEAD, MAKE SURE THAT THE
LUBRICATION CHANNEL IS CLEAN USING A COM-
PRESSED AIR JET.

Locking torques (N*m)

Timing chain tensioner support screw 11 to 13
Fit the pins and rocking levers.
- Lubricate the two rocking levers through the
holes at the top.
- Lubricate the 2 bearings and insert the camshaft
in the cylinder head with the cams corresponding
to the rocking levers.
- Insert the retention plate and tighten the two
screws shown in the figure to the prescribed tor-
que.

Locking torques (N*m)

Plate screws 4 - 6 Nm

ENG - 149
Engine Beverly 300 i.e.

Insert the spacer on the cam shaft.

- Rotate the engine so that the piston is at top dead
centre, using the reference marks on the flywheel
and the crankcase.
- Insert the pulley on the camshaft while keeping
the reference 4V in correspondence with the ref-
erence mark on the head.
- Holding this position insert the chain on the cam-
shaft control pulley.
- Lock the fixing screws.

Locking torques (N*m)

Counterweight screw 7 to 8.5

Set the tensioner cursor to the rest position.

- Fit the chain tensioner on the cylinder, using a
new gasket, and tight the two screws to the pre-
scribed torque.
Insert the chain tensioning screw, together with the
spring and washer, tightening it to the prescribed
torque.

Locking torques (N*m)

Tensioner screws 11 to 13 Tensioner cover 5 - 6
Nm

- Check valve clearance.

Characteristic
Valve clearance
Intake: 0.10 mm Exhaust: 0.15 mm

ENG - 150
Beverly 300 i.e. Engine

Refitting the rocker-arms cover

- Refit the cylinder head cover and tighten the 5

clamping screws to the prescribed torque.
- Make sure the gasket is positioned properly.

Locking torques (N*m)

Tappet cover screws 5 - 6 Nm

Refitting the intake manifold

- Fit the intake manifold and do up the three

screws.

Locking torques (N*m)

Intake manifold screws 11 to 13

Crankcase - crankshaft

Splitting the crankcase halves

AXIAL CLEARANCE CHECK

- Before opening the engine crankcase, it is ad-
visable to check the axial clearance of the crank-
shaft. Use a specific tool to check axial clearance.
- Higher clearances are signs of wear on the crank-
shaft - crankcase supporting surfaces.

Specific tooling
020262Y Crankcase splitting plate
020335Y Magnetic mounting for dial gauge

Characteristic
Axial crankshaft/crankcase clearance: Stand-
ard clearance
0.15 - 0.40 mm (when cold)

ENG - 151
Engine Beverly 300 i.e.

Axial connecting rod - crankshaft clearance

Standard clearance
0.20 to 0.50 mm

CRANKCASE OPENING
- Undo the ten crankshaft coupling screws.
- Separate the crankcase halves while keeping the
crankshaft in one of these two halves.
- Only after the halves have been separated, can
the crankshaft be checked.
CAUTION
WHILE OPENING THE CRANKCASES AND REMOVING
THE CRANKSHAFT, CHECK THAT THE THREADED
SHAFT ENDS DO NOT INTERFERE WITH THE MAIN BUSH-
INGS. FAILURE TO OBSERVE THIS PRECAUTION CAN
DAMAGE THE MAIN BUSHINGS.
CAUTION
KEEP THE CRANKSHAFT IN ONE OF THE TWO HALVES
OF THE CRANKCASE WHEN SEPARATING IT. IF YOU FAIL
TO DO THIS, THE CRANKSHAFT MIGHT ACCIDENTALLY
FALL.

- Remove the crankcase halves gasket and be

careful with the two alignment dowels.

ENG - 152
Beverly 300 i.e. Engine

- Unscrew the oil filter fitting if required.

- Once the crankcase halves have been separa-

ted, reach and remove the internal bulkhead and
the protection bulkhead for the mesh pre-filter.

Inspecting the crankshaft components

N.B.
TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP-
TER.
See also
Crankcase - crankshaft - connecting rod

Inspecting the crankshaft alignment

N.B.
TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP-
TER.
See also
Crankcase - crankshaft - connecting rod

ENG - 153
Engine Beverly 300 i.e.

Inspecting the crankcase halves

- Before proceeding to check the crankcase

halves, thoroughly clean all surfaces and oil ducts.
- On the transmission-side crankcase half, take
particular care when handling the oil pump com-
partment and the oil ducts, the by-pass duct, the
main bushings and the cooling jet on the trans-
mission side (see diagram).
- Take particular care, also, that there are no signs
wear in the oil by-pass valve housing (see Chapter
Lubrication), as this could prevent a good seal in
the piston, which regulates the oil pressure.
- On the flywheel side crankcase half, take partic-
ular care cleaning the oil ducts for the main bush-
ings, the oil duct for the jet that lubricates the
cylinder head and the oil drainage duct at the fly-
wheel side oil seal.
- Inspect the coupling surfaces on the crankcase
halves for scratches or deformation, taking partic-
ular care with the cylinder/crankcase surfaces and
the crankcase halves surfaces.
- Defects in the crankcase coupling gasket be-
tween the crankcase halves or the mating surfaces
shown in the diagram, could cause a drop in the
oil pressure lubricating the main bushings and
connecting rod.
- Check the main bearing seats that limit axial
clearance in the crankshaft show no signs of wear.
The dimension between these seats is measured
by way of the procedure described previously for
measuring the crankshaft axial clearance and di-
mensions.
N.B.
THE JET IS FED THROUGH THE MAIN BUSHINGS. PROP-
ER OPERATION OF THIS COMPONENT IMPROVES PIS-
TON CROWN COOLING. CLOGGING HAS EFFECTS THAT
ARE DIFFICULT TO DETECT (PISTON TEMPERATURE IN-
CREASE). FAILURE OR LEAKS CAN CAUSE A CONSID-
ERABLE DROP IN THE LUBRICATION PRESSURE FOR
MAIN BUSHINGS AND CONNECTING ROD.
N.B.

ENG - 154
Beverly 300 i.e. Engine

THE HEAD LUBRICATION CHANNEL IS PROVIDED WITH

A SHUTTER JET; THIS GIVES A "LOW PRESSURE" HEAD
LUBRICATION; THIS CHOICE WAS MADE TO REDUCE
THE OIL TEMPERATURE IN THE SUMP. THE JET CLOG-
GING IMPAIRS THE HEAD LUBRICATION AND THE TIM-
ING MECHANISMS. A JET FAILURE CAUSES A DE-
CREASE OF THE MAIN BUSHING AND CONNECTING ROD
LUBRICATION PRESSURE.

Inspecting the crankshaft plain bearings

- To obtain a good bushing lubrication it is neces-

sary to have both an optimal lubricating pressure
(3.2 bar) 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 lubrica-
tion 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.
N.B.
TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP-
TER.
See also
Crankcase - crankshaft - connecting rod

Coupling chart
N.B.
TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP-
TER.
See also
Crankcase - crankshaft - connecting rod

ENG - 155
Engine Beverly 300 i.e.

Refitting the crankcase halves

- Fit the internal bulkhead and lock the two screws

to the prescribed torque.
- Fit the oil filter fitting and tighten it to the prescri-
bed torque.
- Position the oil pre-filter element as shown in the
picture.

- Place a new gasket on one of the crankcase

halves, preferably on the transmission side, to-
gether with the alignment dowels.

ENG - 156
Beverly 300 i.e. Engine

- Lubricate the main bushings with engine oil and

insert the crankshaft in the transmission-side
crankcase half.
- Reassemble both crankcase halves.
- Fit the ten screws and tighten them to the pre-
scribed torque.
- Assemble a new O-Ring on the pre-filter and lu-
bricate it with engine oil.
- Insert the filter on the engine with the relative cap.
- Tighten to the specified torque.

Locking torques (N*m)

Internal engine crankcase bulkhead (transmis-
sion-side half shaft) screws 4 to 6 Engine-crank-
case coupling screws 11 to 13 Oil filter on
crankcase fitting 27 to 33 Engine oil drainage
plug/ mesh filter 24 to 30

Studs

Check that the stud bolts have not worked loose

from their seat in the crankcase.
Check the depth of stud bolt driving with a gauge,
as indicated in the picture. If it varies significantly
from the driving depth indicated, it means that the
stud bolt has yielded.
In this case, replace it.

By working on two fitted cylinder head fixing nuts,

nut and lock nut, as shown in the picture, remove
the stud bolt from its seat.
Clean the threaded seat on the carter thoroughly.
Refit a new stud bolt and apply the special product
on the threading crankcase side.
Tighten up to the depth of the driving indicated.

Recommended products
Loctite Quick Set Loctite 270 high strength
threadlock
Loctite 270 high strength threadlock

ENG - 157
Engine Beverly 300 i.e.

Lubrication

Conceptual diagrams

The high pressure circuit is highlighted in blue. The low pressure circuit is highlighted in green
The lobe pump «1» sucks in oil from the sump through the mesh pre-filter «2», pushes it into the car-
tridge filter «3»; the main bushings and the big end are lubricated (with high pressure) through the
suitable passages found in the crankcase halves «4» whereas the piston pin and connecting rod small
end are lubricated via jet «5».
Afterwards, the oil, through a nozzle «6» whose function is to reduce the flow rate, reaches the timing
system where it lubricates the camshaft and from there, the valves and rockers «7». The oil passes
through the timing chain conduit and returns to the sump «8» by gravity

ENG - 158
Beverly 300 i.e. Engine

Oil pressure check

- Remove the electrical minimum oil pressure

switch connection and remove the switch.
- Check that the oil pressure reading is between
0.5 and 1.2 atm with the engine idling at 1650 rpm
and the oil at the required temperature (wait for at
least one electric ventilation).
- Check that the oil pressure is between 3.2 and
4.2 atm with the engine running at 6000 rpm and
the oil at the required temperature.
- Remove the appropriate tools once the meas-
urement is complete, refit the oil pressure switch
and washer, tightening it to the specified torque
and fit the flywheel cover.
- If the oil pressure is not within the specified limits,
in the following order, check: the oil filter, the oil
by-pass valve, the oil pump and the crankshaft
seals.
N.B.
THE CHECK MUST BE CARRIED OUT WITH OIL AT THE
CORRECT LEVEL AND WITH AN OIL FILTER IN PROPER
CONDITION.

Characteristic
Oil pressure
Minimum pressure admitted at 6000 rpm: 3.2 atm.

Locking torques (N*m)

Minimum oil pressure sensor 12 to 14

Crankshaft oil seals

ENG - 159
Engine Beverly 300 i.e.

Removal

- Remove the transmission cover and the com-

plete drive pulley beforehand

- Install the base of the appropriate tool on the oil

seal using the screws provided.

Specific tooling
020622Y Transmission-side oil seal punch

- Screw the threaded bar onto the base of the tool

and extract the oil seal.

Specific tooling
020622Y Transmission-side oil seal punch

Refitting

- Always use a new oil seal upon refitting

- Prepare the new oil guard by lubricating the seal-
ing lip.
- Preassemble the oil seal with the appropriate tool
by positioning the screws.
- Insert the sheath over the crankshaft.
- Insert the tool with the oil seal on the crankshaft
until it comes into contact with the crankcase.
- Insert the adaptor bushing of the tool in the hole
on the crankcase.

ENG - 160
Beverly 300 i.e. Engine

- Orientate the oil seal by inserting the bracket

which is part of the appropriate tool.
- Tighten the threaded bar onto the crankshaft as
far as it will go.
- Use the nut to move the base of the tool until you
can see the end of the oil seal driving stroke
- Remove all the tool components following the
procedure but in reverse order
CAUTION
DO NOT LUBRICATE THE KEYING SURFACE ONTO THE
ENGINE CRANKCASE.
CAUTION
ORIENT THE OIL SEAL BY POSITIONING THE CHAIN
HOUSING CHANNEL FACING DOWNWARDS. WHEN THE
POSITION IS REACHED, DO NOT RETRACT THE OIL
SEAL. FAILURE TO COMPLY WITH THIS RULE CAN
CAUSE A WRONG POSITIONING OF THE OIL SEAL
SHEATH.
CAUTION
FAILURE TO COMPLY WITH THIS ASSEMBLY PROCE-
DURE CAN SERIOUSLY DAMAGE THE ENGINE DUE TO
THE WRONG TENSIONING OF THE OIL PUMP CONTROL
CHAIN.

Specific tooling
020622Y Transmission-side oil seal punch

Oil pump

ENG - 161
Engine Beverly 300 i.e.

Removal

- Undo the two clamping screws in the figure and

remove the cover over the pump control sprocket.

- Block the rotation of the oil pump control pulley

with a screwdriver inserted through one of its two
holes.
- Remove the central screw with Belleville washer,
as shown in the diagram.
- Remove the chain with the crown.
- Remove the control sprocket wheel with relative
O-ring.
- Remove the oil pump by undoing the two screws
in the figure.
- Remove the oil pump seal.
N.B.
IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO EN-
SURE THAT THE INITIAL DIRECTION OF ROTATION IS
MAINTAINED.

Inspection

- Remove the two screws and the oil pump cover.

- Remove the circlip retaining the innermost rotor.
- Remove and wash the rotors thoroughly with pet-
rol and compressed air.
- Reassemble the rotors in the pump body, keep-
ing the two reference marks visible Replace the
retainer ring.

ENG - 162
Beverly 300 i.e. Engine

- Check the clearance between the rotors in the

position shown in the diagram using a feeler
gauge.
Measure the distance between the outer rotor and
the pump body (see figure).
- Check the axial clearance of the rotors using a
trued bar as shown in the figure.

Characteristic
Axial rotor clearance
Limit values admitted: 0.09 mm
Distance between the outer rotor and the pump
body
Admissible limit clearance: 0.20 mm
Distance between the rotors
Admissible limit clearance: 0.12 mm

Refitting

- Check there are no signs of wear on the oil pump

shaft or body.
- Check there are no signs of scoring or wear on
the oil pump cover.
- If you detect non-conforming measurements or
scoring, replace the faulty parts or the unit.
- Fit the pump cover in the position that permits the
crankcase clamping screws to be aligned.
- Make sure the gasket is positioned properly and
refit the pump on the engine crankcase. The pump
can only be fitted in one position. - Tighten the
screws to the prescribed torque.

ENG - 163
Engine Beverly 300 i.e.

- Fit the sprocket wheel with a new O-ring.

- Fit the chain.
- Fit the central screw and the cup washer. Tighten
to the prescribed torque.
-Fit the oil pump cover, by tightening the two
screws to the prescribed torque.
N.B.
FIT THE BELLEVILLE WASHER SO THAT ITS OUTER RIM
TOUCHES THE PULLEY. MAKE SURE THAT THE PUMP
TURNS FREELY.

Locking torques (N*m)

Screws fixing oil pump to the crankcase 5 to 6
Oil pump command sprocket screw 10 to 14 Oil
pump cover screws 0.7 - 0.9

Removing the oil sump

- Drain the oil from the sump.

- Remove the seven screws indicated in the figure
and the bracket of the rear brake pipes.

- Check the correct position of the three alignment

dowels «1» and remove gasket «2», spring and
by-pass piston «3».

ENG - 164
Beverly 300 i.e. Engine

Inspecting the by-pass valve

- Check the unloaded spring length.

- Check that the small piston is not scored.
- Ensure that it slides freely on the crankcase and
that it guarantees a good seal.
- If not, eliminate any impurities or replace defec-
tive parts.

Characteristic
By-pass check up: Standard length
54.2 mm

Refitting the oil sump

- Check the correct position of alignment dowels

«1».
- Fit a new gasket «2».
- Fit the by-pass piston and spring «3».

- Assemble the oil sump by tightening the seven

fixing screws and be careful with the plate indica-
ted.
- Tighten to the specified torque.

Locking torques (N*m)

Oil sump screws 10 to 14

ENG - 165
INDEX OF TOPICS

INJECTION INJEC
Beverly 300 i.e. Injection

COMPONENT LAYOUT
Specification Desc./Quantity
1 Battery 12V - 10Ah
2 Diagnostics socket connector
3 Electric fan solenoid
4 Injection load solenoid
5 Water temperature sensor
6 Throttle body and electronic injection control unit (MIU)
7 Fuel injector
8 HV coil
9 Lambda probe
10 Fuel pump
11 Speed sensor

MIU injection system

This vehicle is fitted with an integrated injection and ignition system.
Injection is indirect in the manifold through an electro-injector.
The injection and ignition are timed on the four-stroke cycle by means of a tone wheel keyed on to the
crankshaft (24-2 teeth) and pick-up sensor.
Combustion and ignition are managed on the basis of engine revs and throttle valve opening. Further
corrections are made according to the following parameters:
- Coolant temperature.
- Intake air temperature
- Lambda probe

INJEC - 167
Injection Beverly 300 i.e.

The system implements an idle feeding correction with cold engine through a Stepper motor on a by-
pass circuit of the throttle valve. The control unit manages the Stepper motor and the injector opening
time, thereby ensuring the idle steadiness and the proper combustion.
In all conditions of use, mixture preparation is managed by modifying the injector opening time.
The fuel system pressure is kept constant based on the ambient pressure.

The fuel system circuit consists of:

- Fuel pump
- Fuel filter
- Injector
- Pressure regulator
The pump, the filter and the regulator are placed inside the fuel tank on a single support.
The injector is connected by two pipes provided with quick couplings. This allows obtaining a continuous
circulation, thereby avoiding the risk of fuel boiling. The pressure regulator is situated at the end of the
circuit.
The fuel pump is controlled by the MIU control unit; this ensures the scooter safety

The ignition circuit consists of:

- HV coil
- HV cable
- Shielded cap
- MIU control unit
- Spark plug
The MIU control unit manages ignition with the best advance ensuring four-stroke timing (ignition only
in the compression phase) at the same time.
The MIU injection-ignition system controls engine functions by means of a pre-set program.
Should any input signals fail, an acceptable working order of the engine is ensured to allow the user to
reach a service station.
Of course, this cannot happen when the rpm-timing signal is missing, or when the failure involves the
control circuits:
- Fuel pump
- HV coil
- Injector

INJEC - 168
Beverly 300 i.e. Injection

The control unit is provided with a self-diagnosis

system connected to an indicator light in the in-
strument panel.

Failures are detected and restored by the diag-

nostic tester.
In any case, when the fault is no longer present,
the data storage is automatically cleared after 16
cycles of use (cold start, running at regular engine
temperature, stop).
The diagnostic tester is also required to adjust the
idle mixture.

Specific tooling
020680Y Diagnosis Tool
The MIU injection-ignition system carries out
checks on the rpm indicator and the electric fan for
radiator cooling.
The MIU control unit has a decoder for the anti-
theft immobilizer system.
The MIU control unit is connected to a diagnostic
LED on the instrument panel, that also carries out
the deterrent flashing functions.

The MIU control unit power supply is furthermore controlled by the emergency switch; that is to provide
further safety for the vehicle.

Precautions

Troubleshooting hints
1 A MIU failure is more likely to be due to the connections than to the components.
Before troubleshooting the MIU system, carry out the following checks:
A: Electrical power supply
a. Battery voltage
b. Blown fuse
c. Remote controls

INJEC - 169
Injection Beverly 300 i.e.

d. Connectors
B: Chassis ground
C: Fuel system
a. Broken fuel pump
b. Dirty fuel filter
D: Ignition system
a. Faulty spark plug
b. Broken coil
c. Broken shielded cap
E: Intake circuit
a. Dirty air filter
b. Dirty by-pass circuit
c. Faulty Stepper motor
F: Other
a. Incorrect distribution timing
b. Wrong idle mixture
c.Incorrect reset of the throttle valve position sensor
2 MIU system faults may be caused by loose connectors. Make sure that all connections have been
correctly made.
Check the connections as follows:
A check that the terminals are not bent.
B check that the connectors have been properly connected.
C check whether the malfunction can be fixed by shaking the connector slightly.
3 Check the entire system before replacing the MIUIf the fault is fixed by replacing the MIU control unit,
install the original control unit again and check if the fault occurs again.
4 Use a multimeter with an internal resistance of more than 10K Ohm /V when troubleshooting. Instru-
ments that are not suitable might damage the MIU central control unit. Use instruments with definitions
over 0.1V and 0.5 W , the precision must be greater than 2%.

1. Before fixing any part of the injection system, check to see if there are any registered faults. Do not
disconnect the battery before checking for faults.
2. The fuel supply system is pressurised at 250 kPa (2.5 BAR). Before disconnecting the fast-release
fitting of the fuel supply pipe, check that there are no naked flames. Do not smoke. Act with caution to
avoid spraying fuel to your eyes.
3. When fixing electric components, operate with the battery connected only when actually required.
4. When functional checks are performed, check that the battery voltage is over 12V.
5. Before any attempt to start the vehicle, check to make sure there is at least two litres of fuel in the
tank. Failure to respect this norm will damage the fuel pump.

INJEC - 170
Beverly 300 i.e. Injection

6. If the vehicle is expected to remain unused for a long time, refill the tank up to a little over half the
level. This will ensure the pump will be covered by fuel.
7. When washing the vehicle, be careful with the electric components and cable harnesses.
8. When an ignition problem is detected, start the checks from the battery and the injection system
connections.
9. Before disconnecting the MIU ECU connector, perform the following steps in the order shown:
- Set the switch to «OFF»
- Disconnect the battery
Failure to respect this norm may damage the control unit.
10. Do not invert the poles when fitting the battery.
11. To avoid causing any damage, disconnect and reconnect the MIU system connectors only if re-
quired. Before reconnecting, check that the connectors are dry.
12. When carrying out electric inspections, do not force the tester probes into the connectors. Do not
take measurements not specifically foreseen by the manual.
13. At the end of every check performed with the diagnostic tester, remember to protect the system
connector with its cap. Failure to observe this precaution may damage the MIU control unit.
14. Before reconnecting the quick couplers of the power supply system, check that the terminals are
perfectly clean.

Terminals setup

INJEC - 171
Injection Beverly 300 i.e.

TERMINAL LAYOUT
Specification Desc./Quantity
1 Injection telltale light
2 -
3 -
4 Lambda probe negative
5 Live supply
6 Battery-powered
7 Immobilizer aerial
8 Electric fan solenoid
9 Water temperature sensor
10 -
11 Lambda probe positive
12 engine stop switch
13 Engine speed sensor (+)
14 Fuel injector
15 Engine speed sensor (-)
16 Diagnostics socket output
17 Immobilizer LED
18 Side stand
19 -
20 Injection load solenoid
21 -
22 HV coil
23 -
24 Start up enabling
25 -
26 Ground lead Connected with: water temperature sensor, stand witch
and engine stop switch.

EMS circuit diagram

INJEC - 172
Beverly 300 i.e. Injection

SYSTEM DIAGRAM
Specification Desc./Quantity
1 Injection ECU
2 Diagnostics socket connector
3 Fuel pump
4 Water temperature sensor
5 Fuel injector
6 HV coil
7 Speed sensor
8 Lambda probe
9 Injection load solenoid
10 Start-up solenoid
11 Battery 12V - 12 Ah
12 Main fuses
13 Electric fan solenoid
14 Electric fan
15 Stand switch
16 engine stop switch
17 Ignition key contacts
18 Auxiliary fuses
19 Immobilizer LED
20 "WARNING" light
21 Water temperature gauge
22 Immobilizer aerial
23 Fall sensor
24 Voltage regulator
25 Magneto flywheel

Troubleshooting procedure

Engine does not start

ENGINE DOES NOT START IF ONLY PULLED

Possible Cause Operation
Immobiliser enabling signal System not encoded
System not efficient, repair according to the indications of the
self-diagnosis
Presence of faults detected by the self diagnosis Pump relay
HV coil
Injector
Revolution timing sensor
Fuel system Fuel in the tank
Fuel pump activation
Fuel pressure (low)
Injector capacity (low)
Power to the spark plug Shielded spark plug cap HV coil (secondary insulation)
Parameter reliability Coolant temperature
Distribution timing - injection ignition
Intake air temperature
End of compression pressure End of compression pressure

Starting difficulties

ENGINE START-UP PROBLEMS

Possible Cause Operation
Presence of faults detected by the self diagnosis Pump relay
HV coil
Injector
Revolution timing sensor

INJEC - 173
Injection Beverly 300 i.e.

Possible Cause Operation

Air temperature
Coolant temperature
Start-up speed Starter motor and solenoid
Battery
Ground connections
End of compression pressure End of compression pressure
Power to the spark plug Spark plug
Shielded cap
HV coil
Speed-timing sensor
Ignition advance
Fuel system Fuel pressure (low)
Injector capacity (low)
Injector sealing (poor)
Correctness of the parameters Coolant temperature
Stepper throttle valve position intake air temperature (steps
and actual opening)
Cleaning of the auxiliary air pipe and throttle valve; air filter ef-
ficiency

Engine stops at idle

ENGINE DOES NOT IDLE/ IDLING IS UNSTABLE/ IDLING TOO LOW

Possible Cause Operation
Presence of faults detected by the self diagnosis Pump relay
HV coil
Injector
Revolution timing sensor
Air temperature
Coolant temperature
Ignition efficiency Spark plug
Ignition timing
Correctness of the parameters Throttle valve position sensor
Stepper
Coolant temperature sensor
Intake air temperature sensor
Intake system cleaning Air filter
Diffuser and throttle valve
Additional air pipe and Stepper
Intake system sealing (infiltrations) Intake manifold - head
Throttle body - manifold
Intake sleeve
Filter box
Fuel system (low pressure) Fuel pump
Pressure regulator
Fuel filter
Injector capacity

Engine does not rev down

ENGINE DOES NOT RETURN TO IDLING SPEED/IDLING SPEED TOO HIGH

Possible Cause Operation
Presence of faults detected by the self diagnosis Pump relay
HV coil
Injector
Revolution timing sensor
Air temperature
Coolant temperature
Ignition efficiency Ignition timing
Correctness of the parameters Throttle valve position sensor
Stepper
Coolant temperature sensor
Intake air temperature sensor

INJEC - 174
Beverly 300 i.e. Injection

Possible Cause Operation

Intake system sealing (infiltrations) Intake manifold - head
Throttle body - manifold
Intake sleeve
Filter box
Fuel system (low pressure) Fuel pump
Pressure regulator
Fuel filter
Injector capacity

Exhaust backfires in deceleration

EXHAUST BACKFIRES WHEN DECELERATING

Possible Cause Operation
Presence of faults detected by the self diagnosis Pump relay
HV coil
Injector
Revolution timing sensor
Air temperature
Coolant temperature
Lambda probe
Correctness of the parameters Throttle valve position sensor
Stepper
Coolant temperature sensor
Intake air temperature sensor
Intake system sealing (infiltrations) Intake manifold - head
Throttle body - manifold
Intake sleeve
Filter box
Fuel system (low pressure) Fuel pump
Pressure regulator
Fuel filter
Injector capacity
Exhaust system sealing (infiltrations) Manifold - head
Manifold - silencer
silencer welding

Engine revs irregularly

ENGINE IRREGULAR PERFORMANCE WITH VALVE SLIGHTLY OPEN

Possible Cause Operation
Intake system cleaning Air filter
Diffuser and throttle valve
Additional air pipe and Stepper
Intake system sealing Intake sleeve
Filter box
Ignition system Spark plug wear check
Parameter reliability Throttle valve position signal
Coolant temperature indicator
Intake air temperature indicator
Ignition advance
TPS reset successful TPS reset successful
Presence of faults detected by the self diagnosis Pump relay
HV coil
Injector
Revolution timing sensor
Air temperature
Coolant temperature
Lambda probe

INJEC - 175
Injection Beverly 300 i.e.

Poor performance at full throttle

POOR ENGINE PERFORMANCE AT FULL POWER/ ENGINE IRREGULAR PERFORM-

ANCE ON PICKUP
Possible Cause Operation
Presence of faults detected by the self diagnosis Pump relay
HV coil
Injector
Revolution timing sensor
Air temperature
Coolant temperature
Lambda probe
Spark plug power supply Spark plug
Shielded cap
HV cable
HV coil
Intake system Air filter
Filter box (sealing)
Intake sleeve (sealing)
Parameter reliability Throttle valve position signal
Coolant temperature indicator
Intake air temperature indicator
Ignition advance
Fuel system Fuel level in the tank
Fuel pressure
Fuel filter
Injector capacity

Engine knocking

PRESENCE OF KNOCKING (COMBUSTION SHOCKS)

Possible Cause Operation
Presence of faults detected by the self diagnosis Pump relay
HV coil
Injector
Revolution timing sensor
Air temperature
Coolant temperature
Lambda probe
Ignition efficiency Spark plug
Parameter reliability Throttle valve position signal
Coolant temperature indicator
Intake air temperature indicator
Ignition advance
Intake system sealing Intake sleeve
Filter box
TPS reset successful TPS reset successful
Fuel system Fuel pressure
Fuel filter
Injector capacity
Fuel quality
Selection of the cylinder base gasket thickness Selection of the cylinder base gasket thickness

Fuel supply system

The fuel supply circuit includes the electric pump, the filter, the pressure regulator, the electro-injector
and the fuel delivery pipes.
The electrical pump is located in the tank from which the fuel is pumped and sent to the injector through
the filter.
The pressure is controlled by the pressure regulator situated in the pump assembly in the tank.

INJEC - 176
Beverly 300 i.e. Injection

Removing the butterfly valve

Remove the fuel piping clamping screw indicated

in the figure.

INJEC - 177
Injection Beverly 300 i.e.

Remove the fast-release fittings from the injector

support.

Remove the injector connector.

Remove the three screws fixing the manifold to the

cylinder head and the clip fixing the throttle body
to the manifold.

INJEC - 178
Beverly 300 i.e. Injection

Remove the MIU ECU connector.

Remove the clip fixing the throttle body to the air

cleaner bellows.

Remove the gas command fitting as indicated in

the picture

Refitting the butterfly valve

To refit, perform the operations in the reverse or-

der from the removal operations being careful to
position the clip fixing the throttle body to the air
filter bellows at 45° as shown in the photograph.

INJEC - 179
Injection Beverly 300 i.e.

Pump supply circuit

INJECTION LOADS
Specification Desc./Quantity
1 Battery 12V - 12 Ah
2 Fuse No. 3 10 A
3 Fuse No. 1 30 A
4 Ignition key contacts
5 Fuse No. 6 5A
6 Injection load solenoid
7 Fuel pump
8 HV coil
9 Fuel injector
10 Injection ECU
11 Electric fan solenoid

When switched to «ON», the fuel pump starts to rotate for 2 seconds and then stops. When the engine
starts, in the presence of rpm timing signal the pump is continuously supplied.
ELECTRICAL DATA

• Pump winding resistance ~ 1.5 Ohm

• Input current during normal functioning 1.4 to 1.8 A
• Input current to the closed hydraulic circuit ~ 2 A (to be checked with specific tool for fuel
pressure control, choking the circuit on the return pipe)

INJEC - 180
Beverly 300 i.e. Injection

Check function of fuses No. 3 and 6 for the ECU

and injection load solenoid.

Check the efficiency of the injection load solenoid.

Check the resistance of the energising coil be-
tween pins 86 and 85: 40 to 80 Ohm
Apply a voltage of 12V to pins 86 and 85; make
sure that there is continuity between pins 30 and
87 of the solenoid.

WARNING
TO INDICATE THE SOLENOID OF THE DESIRED FUNC-
TION, REFER TO THE PIN-CABLE COLOUR RELATION-
SHIP WITH THE ATTACHED ELECTRIC SYSTEM DIA-
GRAM.

INJEC - 181
Injection Beverly 300 i.e.

Check the power supply line of the injection load

solenoid energising coil: after switching to «ON»,
make sure there is battery voltage, for 2 seconds,
between the Red-White cable and the Black-Pur-
ple cable of the solenoid base. If there is not, check
the continuity of the Red-White cable between the
fuse box and the solenoid base and of the Black-
Purple cable between the pin 20 of the control unit
and the solenoid base.
N.B.
CONTINUITY TESTS MUST BE CARRIED OUT WITH THE
COMPONENTS DISCONNECTED. (SOLENOIDS, CON-
TROL UNIT, FUSES ETC.).

Check for continuous voltage between the grey/

black cable of the solenoid base and ground. If no
voltage is measured, check continuity of the Grey/
Black cable between the fuse box (No. 3, 5A) and
the solenoid base.
N.B.
CONTINUITY TESTS MUST BE CARRIED OUT WITH THE
COMPONENTS DISCONNECTED. (SOLENOIDS, CON-
TROL UNIT, FUSES ETC.).

INJEC - 182
Beverly 300 i.e. Injection

After switching to «ON», check that there is battery

voltage, for about 2 seconds, between the Black-
Green cable of the pump connector and the
ground lead with the pump connector disconnec-
ted. Otherwise, check the continuity of the Black-
Green cable between the pump connector and the
solenoid base.
Check the efficiency of the ground line of the fuel
pump by measuring the continuity between the
pump connector black cable, system side, and the
ground.
If, when switching to «ON», the pump continues to
turn after 2 seconds of activation, check, with the
control unit disconnected and the injection load
solenoid disconnected, that the Black-Purple ca-
ble (pin 20 on the interface wiring) is insulated from
the ground.

Specific tooling
020331Y Digital multimeter

Circuit leak test

Install the specific tool for checking the fuel pressure, with the pipe fitted with the gauge.
Check during regular operation by placing the ap-
propriate tool between the pump and the injector.
With the battery voltage> 12 V check that the fuel
pressure is 2.5 BAR and that the input current is
1.4 to 1.8 A

With the battery voltage > 12 V, check the pump flow rate by disconnecting from the injector the pipe
equipped with the pressure gauge of the appropriate tool. Get a graded burette with a flow rate of
approximately 1 L. Rotate the pump using the active diagnoses of the palm top computer. Using a pair

INJEC - 183
Injection Beverly 300 i.e.

of long flat needle-nose pliers, choke the fuel pipe making the pressure stabilise at approx. 2.5 BAR.
Check that within 15 seconds the pump has a flow rate of approx. 110 cm³.

Specific tooling
020480Y Petrol pressure check kit

Fuel filter check

Disconnect the terminals from the electric pump

Remove the screw shown in the picture

Remove the clip fixing the piping to the filter shown

in the picture

INJEC - 184
Beverly 300 i.e. Injection

Separate the lower part of the pump mounting as

shown in the picture.

Remove the filter from the pump mounting

Inspecting the injector circuit

INJECTION LOADS
Specification Desc./Quantity
1 Battery 12V - 12 Ah
2 Fuse No. 3 10 A
3 Fuse No. 1 30 A

INJEC - 185
Injection Beverly 300 i.e.

Specification Desc./Quantity
4 Ignition key contacts
5 Fuse No. 6 5A
6 Injection load solenoid
7 Fuel pump
8 HV coil
9 Fuel injector
10 Injection ECU
11 Electric fan solenoid

Check the resistance at the injector ends: 14.5 ± 5% Ohm

Check function of fuses No. 3 and 6 for the ECU

and injection load solenoid.

Check the efficiency of the injection load solenoid.

Check the resistance of the energising coil be-
tween pins 86 and 85: 40 to 80 Ohm
Apply a voltage of 12V to pins 86 and 85; make
sure that there is continuity between pins 30 and
87 of the solenoid.

INJEC - 186
Beverly 300 i.e. Injection

WARNING
TO INDICATE THE SOLENOID OF THE DESIRED FUNC-
TION, REFER TO THE PIN-CABLE COLOUR RELATION-
SHIP WITH THE ATTACHED ELECTRIC SYSTEM DIA-
GRAM.

Check the power supply line of the injection load

solenoid energising coil: after switching to «ON»,
make sure there is battery voltage, for 2 seconds,
between the Red-White cable and the Black-Pur-
ple cable of the solenoid base. If there is not, check
the continuity of the Red-White cable between the
fuse box and the solenoid base and of the Black-
Purple cable between the pin 20 of the control unit
and the solenoid base.
N.B.
CONTINUITY TESTS MUST BE CARRIED OUT WITH THE
COMPONENTS DISCONNECTED. (SOLENOIDS, CON-
TROL UNIT, FUSES ETC.).

INJEC - 187
Injection Beverly 300 i.e.

Check for continuous voltage between the grey/

black cable of the solenoid base and ground. If no
voltage is measured, check continuity of the Grey/
Black cable between the fuse box (No. 3, 5A) and
the solenoid base.
N.B.
CONTINUITY TESTS MUST BE CARRIED OUT WITH THE
COMPONENTS DISCONNECTED. (SOLENOIDS, CON-
TROL UNIT, FUSES ETC.).

With the control unit and the injector disconnected,

check the continuity of the Red-Yellow cable be-
tween pin 14 of the interface wiring and the injector
connector

Switch to «ON» and check if there is voltage, with

injector disconnected and control unit connected,
between the Black-Green cable of the injector con-
nector and the ground lead

With injector disconnected and the injector load

solenoid disconnected, check the continuity of the
Black-Green cable between the injector connector
and solenoid base.

INJEC - 188
Beverly 300 i.e. Injection

Inspecting the injector hydraulics

To carry out the injector check, remove the intake

manifold by removing the three clamping screws
at the head and the clip connecting the control unit
to the manifold.

Install the appropriate tool for checking fuel pres-

sure and position the manifold over a container
graduated by at least 100 cm³. Connect the injec-
tor with the cable making up part of the supply for
the injection tester. Connect the clamps of the ca-
ble to an auxiliary battery. Activate the fuel pump
with the active diagnosis. Check that, within fifteen
seconds, approximately 40 cm³ of fuel is dis-
pensed with an adjustment pressure of approxi-
mately 2.5 BAR.

Specific tooling
020480Y Petrol pressure check kit

INJEC - 189
Injection Beverly 300 i.e.

Proceed with the injector seal test.

Dry the injector outlet with a blast of compressed
air. Activate the fuel pump. Wait for one minute,
making sure there are no leaks coming from the
injector. Slight oozing is normal.
Value limit = 1 drop per minute

Components location

COMPONENT LAYOUT
Specification Desc./Quantity
1 Battery 12V - 10Ah
2 Diagnostics socket connector
3 Electric fan solenoid
4 Injection load solenoid
5 Water temperature sensor
6 Throttle body and electronic injection control unit (MIU)
7 Fuel injector
8 HV coil
9 Lambda probe
10 Fuel pump
11 Speed sensor

INJEC - 190
Beverly 300 i.e. Injection

Tachometer

With wiring disconnected from the control unit and

connected to the system, check that the sensor
resistance between pins 13 - 15 is between 100
and 150 Ohm at an engine temperature of approx-
imately 20°

Disconnect the fuel pipe connector. Start up the engine and wait for it to stop. With the wiring connected
to the control unit and system try to start up the engine and check that the voltage between pins 13 and
15 is around 2.8 V

With the interface cable harness disconnected

from the control unit, check continuity between pin
13 and the red cable of the engine speed sensor
connector and between pin 15 and the brown ca-
ble of the engine speed sensor connector

INJEC - 191
Injection Beverly 300 i.e.

With the interface wiring and rpm sensor connec-

tor disconnected from the control unit, check that
the Red and Brown cables (pin 13 - 15) are isola-
ted from each other and insulated from the ground.

Specific tooling
020481Y Control unit interface wiring
020331Y Digital multimeter

HT coil

INJECTION LOADS
Specification Desc./Quantity
1 Battery 12V - 12 Ah
2 Fuse No. 3 10 A
3 Fuse No. 1 30 A
4 Ignition key contacts
5 Fuse No. 6 5A
6 Injection load solenoid
7 Fuel pump
8 HV coil
9 Fuel injector
10 Injection ECU
11 Electric fan solenoid
The ignition system is integrated with the injection and it is a high-efficiency inductive type ignition.
The control unit manages two important parameters:
- Ignition advance
This is optimised according to the engine rpm, to the engine load, temperature and ambient pressure

INJEC - 192
Beverly 300 i.e. Injection

With idle engine, it is optimised to obtain the stabilisation of the speed at 1450 ± 50 R/1'.
- Magnetisation time
The coil magnetisation time is controlled by the control unit. The ignition power is increased during the
engine start-up phase.
The injection system recognises the 4-stroke cycle and therefore, ignition is only controlled during
compression.

Specific tooling
020331Y Digital multimeter

Check function of fuses No. 3 and 6 for the ECU

and injection load solenoid.

Check the efficiency of the injection load solenoid.

Check the resistance of the energising coil be-
tween pins 86 and 85: 40 to 80 Ohm
Apply a voltage of 12V to pins 86 and 85; make
sure that there is continuity between pins 30 and
87 of the solenoid.

INJEC - 193
Injection Beverly 300 i.e.

WARNING
TO INDICATE THE SOLENOID OF THE DESIRED FUNC-
TION, REFER TO THE PIN-CABLE COLOUR RELATION-
SHIP WITH THE ATTACHED ELECTRIC SYSTEM DIA-
GRAM.

Check the power supply line of the injection load

solenoid energising coil: after switching to «ON»,
make sure there is battery voltage, for 2 seconds,
between the Red-White cable and the Black-Pur-
ple cable of the solenoid base. If there is not, check
the continuity of the Red-White cable between the
fuse box and the solenoid base and of the Black-
Purple cable between the pin 20 of the control unit
and the solenoid base.
N.B.
CONTINUITY TESTS MUST BE CARRIED OUT WITH THE
COMPONENTS DISCONNECTED. (SOLENOIDS, CON-
TROL UNIT, FUSES ETC.).

INJEC - 194
Beverly 300 i.e. Injection

Check for continuous voltage between the grey/

black cable of the solenoid base and ground. If no
voltage is measured, check continuity of the Grey/
Black cable between the fuse box (No. 3, 5A) and
the solenoid base.
N.B.
CONTINUITY TESTS MUST BE CARRIED OUT WITH THE
COMPONENTS DISCONNECTED. (SOLENOIDS, CON-
TROL UNIT, FUSES ETC.).

Check there is voltage between pins 22 and 26 of

the interface wiring for around two seconds when
switching to «ON».

Check the resistance of the primary coil between

pin 22 of the interface wiring and the green black
cable of the injection load solenoid base with the
control unit disconnected and the solenoid discon-
nected.
Resistance of the primary = 0.5 ± 8% Ohm

INJEC - 195
Injection Beverly 300 i.e.

Coolant temperature sensor

TEMPERATURE SENSOR
Specification Desc./Quantity
1 Instrument panel
2 Injection ECU
3 Water temperature sensor

With the connector on the control unit side discon-

nected and the coolant temperature sensor con-
nector connected, check that the resistance val-
ues between pin 9 and the ground lead correspond
with the engine temperature.
20° = 2500 ± 100 Ω
80° = 308 ± 6 Ω
With the connector on the control unit side discon-
nected and the coolant temperature connector dis-
connected, check the insulation between the light-
blue/green cable and ground lead.

INJEC - 196
Beverly 300 i.e. Injection

With the connector on the control unit side discon-

nected and the coolant temperature connector dis-
connected, check the continuity between pin 9 of
the interface cable harness and the light-blue/
green cable of the connector.

Specific tooling
020481Y Control unit interface wiring
020331Y Digital multimeter

Zeroing the throttle

Resetting the throttle valve position signal (TPS reset)

The MIU control unit is supplied with a throttle valve position sensor that is pre-calibrated.
Pre-calibration entails regulating the minimum opening of the throttle valve to obtain a certain flow of
air under pre-set reference conditions.
Pre-calibration ensures optimal air flow to control idling.
This regulation must not be tampered with in any way whatsoever.
The injection system will complete the management of the idling through the Stepper motor and the
variation of the ignition advance.
The throttle body after the pre-calibration has an opened valve with an angle that can vary depending
on the tolerances of the machining of the pipe and the valve itself.
The valve position sensor can also assume various fitting positions. For these reasons the mV of the
sensor with the valve at idle can vary from one throttle body to another.
To obtain the optimum fuel mixture, especially at small openings of the throttle valve, it is essential to
match the throttle body with the control unit following the procedure known as TPS resetting.
With this operation we inform the control unit, as the starting point, of the mV value corresponding to
the pre-calibrated position.
To reset, proceed as follows.

Connect the diagnostic tester.

Switch to «ON».
Select the functions of the diagnostic tester on
«TPS RESET».

Specific tooling
020680Y Diagnosis Tool

INJEC - 197
Injection Beverly 300 i.e.

Make sure that the throttle valve with the control is

supporting the stop screw.

Guaranteeing that this position will be kept, send

a confirmation for the TPS reset procedure.

Reset should be performed in the following cases:

- on first fitting.
- if the injection control unit is replaced.
N.B.
THE TPS RESET PROCEDURE MUST NOT BE CARRIED OUT WITH A USED THROTTLE BODY
BECAUSE POSSIBLE VALVE WEAR AND STOP WEAR FOR THE MINIMUM OPENING MAKE THE
AIR FLOW DIFFERENTLY FROM THAT OF PRE-CALIBRATION.

INJEC - 198
Beverly 300 i.e. Injection

Given that the TPS resetting is also done when the

control unit is replaced, place the control unit - filter
box bellows at 45° during the refitting operation as
shown in the picture.

Lambda probe

LAMBDA PROBE
Specification Desc./Quantity
1 Lambda probe
2 Injection ECU

PIN RELATIONSHIP
PIN PIN Component Reference value
4 11 Lambda probe ~ 0V with throttle valve closed; ~ 1V with
throttle valve fully opened

The Lambda sensor or oxygen sensor is a sensor which provides indications concerning the oxygen
content in the exhaust gas. The signal generated is not of the proportional type but of the ON/OFF type,
i.e. there is oxygen or there is not. The sensor is positioned on the exhaust manifold before the catalytic
converter in an area where the gas temperature is always high. The temperature at which the sensor

INJEC - 199
Injection Beverly 300 i.e.

works is at least 350°C at 600°C and it has a reaction time of just 50 milliseconds. The signal generated
passes from a high value to a low value with a mixture with lambda =1.

CONTROLLO DEL SEGNALE

Install the electronic control unit interface wiring.

Start the engine and warm up until the electric fan
switches on.
Use an analogue multimeter with a direct voltage
scale measuring down to 2 V.
Place the tips of the multimeter between pins 4 (-)
and 11 (+)

With the engine running at idle speed, check that

the voltage oscillates between 0V and 1V
With the throttle valve completely open, the volt-
age is approx. 1V.
During the closing phase, the voltage is approx.
0V.
If the voltage remains constant, the sensor may be
damaged. Remove the sensor and check that
there are no oil or carbon deposits inside it..

INJEC - 200
INDEX OF TOPICS

SUSPENSIONS SUSP
Suspensions Beverly 300 i.e.

Front

Removing the front wheel

- Remove the front brake calliper.

- Loosen the wheel axle lock-nut.

- Loosen the two wheel axle safety screws on the

fork leg, on the brake calliper side.

- Pull out the wheel axle.

See also
Removal

Front wheel hub overhaul

Check that the wheel bearings do not show signs

of wear.
If you have to replace the wheel bearings, proceed
as follows:
- Remove the plastic cover on the tone wheel side
to avoid damage by loosening the 5 fixing screws.
- Remove the two bearings on the odometer drive
side using the pliers 14 or 34 and the bell detail 9.
- Remove the internal spacer.

SUSP - 202
Beverly 300 i.e. Suspensions

* Either tool can be used.

- Support the front wheel with two wooden shims

that make it possible to avoid scratching in the
case of contact with the rim.
- Insert the punch (consisting of adaptor handle,
15 mm adaptor and guide) from the odometer drive
side to permit the removal of the brake disc side
bearing and the spacer bushing.

Specific tooling
020376Y Adaptor handle
020456Y Ø 24 mm adaptor
020412Y 15-mm guide
- Heat the bearing seat on the side the brake disc
with the heat gun.

- Insert the bearing using the punch consisting of

adaptor handle, 42x47 mm adaptor and 15 mm
guide, and drive it up to the stop.

SUSP - 203
Suspensions Beverly 300 i.e.

- Reinsert the spacer bushing on the brake disc

side using the appropriate tool and take it to the
stop.

Specific tooling
020376Y Adaptor handle
020359Y 42x47-mm Adaptor
020412Y 15-mm guide
020201Y Spacer bushing driving tube
- Turn over the wheel and insert the internal spacer
with the part fitted with the Seeger ring facing the
bearing on the brake disc side installed previously.

- Heat the bearing seat on the odometer drive side

with the heat gun.

- Insert the two bearings using the punch consist-

ing of adaptor handle, 32x35 mm adaptor and 15
mm guide, and drive it up to the stop.

Specific tooling
020376Y Adaptor handle
020357Y 32x35-mm Adaptor
020412Y 15-mm guide

SUSP - 204
Beverly 300 i.e. Suspensions

Refitting the front wheel

- Grease the wheel axle, then install it from the

tone wheel side and install the tone wheel proper-
ly.
- Tighten the wheel axle nut to the prescribed tor-
que.
N.B.
TAKE CARE NOT TO DAMAGE THE ODOMETER DRIVE.
FOR THE SAKE OF SAFETY, OFFSET THE INTERNAL
STOP FROM THE STOP OF THE TONE WHEEL BY 90°.

- Tighten the two safety screw on the leg to the

prescribed torque.

Locking torques (N*m)

Front wheel axle nut 45 - 50 Safety screw on fork
leg 6 - 7

Handlebar

Removal

- Remove the rear handlebar cover.

- Remove the pin mounting the handlebar to the
steering tube.
- Remove the handlebar and place it on the rear
cover of the legshield.

See also
Rear handlebar cover

SUSP - 205
Suspensions Beverly 300 i.e.

Refitting

- Install the handlebar on the steering tube, paying

attention to the centring, aligning the recess on the
handlebar with that on the steering tube as shown
in the figure.
- Tighten the handlebar fixing screw on the steer-
ing tube to the prescribed torque.

Locking torques (N*m)

Handlebar fixing screw (*) 45 to 50
(*) Lubricate the nuts with engine oil before installation

Front fork

Removal

Overhaul

- Support the fork in a vice.

- Loosen the two tightening screws of the stem
supporting clamp.
- Unscrew the stem closing cap and slide off the
complete fork leg from the corresponding support.
CAUTION
THE STEM CLOSING CAP KEEPS THE MAIN SPRING PRE-
LOADED. KEEP THE CAP PROPERLY FITTED DURING
THE REMOVAL FINAL STAGE TO AVOID ACCIDENTS.

- Support the fork leg properly, remove the main

spring and drain off the fork leg oil.

SUSP - 206
Beverly 300 i.e. Suspensions

- Remove the hydraulic rod fixing screw with the

corresponding sealing gasket:
- With a 19-mm hexagonal spanner, lock hydraulic
rod rotation.
- Undo the fixing screw and collect the copper
washer.

- Remove the stem dust guard with a screwdriver.

- Remove the circlip retaining the oil seal.

SUSP - 207
Suspensions Beverly 300 i.e.

- Take out the stem.

- Check there are no signs of wear or seizing between the stem and the fork leg. Otherwise, replace
the damaged parts.

Characteristic
Maximum fork leg diameter
35.10 mm
Minimum stem diameter
34.90 mm

- Take out the oil seal using the appropriate tools.

- Fit the tie rod into the oil seal.
- Insert in sequence the two half-rings per Ø 35-
mm stems.

Specific tooling
020487Y Fork oil seal extractor

- Hold the tie rod manually so that it does not fall

into the fork leg and/or that both half-rings are not
in their position.
- Fit the bell.
- Tighten the nut until it stops.
- Act on the tool until the oil seal is completely re-
moved.

Specific tooling
020487Y Fork oil seal extractor

SUSP - 208
Beverly 300 i.e. Suspensions

- Remove the hydraulic rod with the corresponding

sealing gasket, the spring and the stop bushing.

COMPONENT CHECK
CAUTION
CLEAN ALL THE COMPONENTS THOROUGHLY.
- Check that the fork leg is not cracked or broken
in the attachments.
- Check that the stem is not scored, dented or dis-
torted.
- Check that the stop bushing for the hydraulic rod
is correctly fixed through caulking.

SUSP - 209
Suspensions Beverly 300 i.e.

- Check that hydraulic rod caulkings, the return

spring to the unloaded the end of stroke and the
hydraulic rod sealing ring are in good conditions.

- Check that the main spring exhibits no signs of

yielding or abnormal wear.

- Check that the closing cap O-ring of the stem is

in good conditions.

Refitting

- First grease the splitting chamber of the two seal-

ing lips of a new oil seal.
- Fit the sealing ring on the stem and keep the
identification words facing upwards.
- Drive the oil seal as far as it will go using the ap-
propriate tool.

Specific tooling
020376Y Adaptor handle
020359Y 42x47-mm Adaptor

SUSP - 210
Beverly 300 i.e. Suspensions

- Pre-fit the stem with the hydraulic rod, the spring

and the stop bushing.
- Fit the pre-assembled components inside the fork
leg.

- Fit the hydraulic rod fixing screw with the copper

sealing washer and tighten to the prescribed tor-
que using the recommended product.
CAUTION
ALWAYS USE NEW COPPER WASHER.

Locking torques (N*m)

Hydraulic rod fixing screw 25 ÷ 35*

(°) Apply LOCTITE 243 threadlock

- Lock hydraulic rod rotation using a 19-mm hex-

agonal spanner.

- Fit the oil seal retaining circlip.

SUSP - 211
Suspensions Beverly 300 i.e.

- Grease and fit a new dust guard.

- Fit the fork leg together with the stem on the fork
supporting clamp until it stops.
- Tighten the two screws to the prescribed torque
in the sequence indicated in the picture.

Locking torques (N*m)

Stem support clamp tightening screws 20 to 25

- Refill the fork leg with the recommended product

to the prescribed amount.

Recommended products
AGIP FORK 7.5 W Oil for front fork
Hydraulic fluid SAE 7.5 W

Characteristic
Oil quantity per stem
133 ± 3 cm³

- Bleed the hydraulic rod by actuating the stem re-

peatedly.
- Fit the spring into the stem.

SUSP - 212
Beverly 300 i.e. Suspensions

- Lubricate the closing cap O-ring of the stem.

- Preload the spring, fit the closing cap and tighten
to the prescribed torque.

Locking torques (N*m)

Fork locking screws cap 15 ÷ 30

- Repeat the procedure for the other fork leg.

N.B.
IF BOTH FORK LEGS ARE SERVICED AT THE SAME TIME, BE CAREFUL NOT TO INVERT THE
RIGHT FORK LEG WITH THE LEFT ONE.

Steering column

Removal

- Remove the front wheel.

- Remove the front mudguard
- Remove the front brake calliper
- Remove the front and rear handlebar covers.
- Remove the pin mounting the handlebar to the
steering tube.
- Remove the handlebar and rest it on the shield
back plate.

SUSP - 213
Suspensions Beverly 300 i.e.

- Remove by releasing the cable passages and

sliding the protection collar upwards.

Using the special tool, loosen and remove the up-

per ring nut, the spacer washer and the counter-
lock ring.
- Extract the fork.
N.B.
TAKE CARE TO SUPPORT THE FORK SO AS TO PREVENT
IT FROM COMING OFF ABRUPTLY

Specific tooling
020055Y Wrench for steering tube ring nut

Refitting

- Fit the lower steering bearing on the steering

tube.
- Fit the fork together with the lower steering bear-
ing on the headstock and hold it so that it does not
fall.
N.B.
LUBRICATE THE STEERING FIFTH WHEEL TRACKS WITH
RECOMMENDED GREASE BEFORE USE.

Recommended products
AGIP GREASE PV2 Grease for steering bear-
ings, bolt seatings for swinging arms and fay-
ing surface of driven pulley spring (only pulley
side)
Soap-based lithium and zinc oxide grease con-
taining NLGI 2; ISO-L-XBCIB2

SUSP - 214
Beverly 300 i.e. Suspensions

- Fit the upper steering bearing.

CAUTION
INSERT THE UPPER STEERING BEARING WITH THE
CAGE FACING UPWARDS.

- Fit the steering bearing upper seat.

- Fit the cover plate.

- Insert the lower tightening ring nut, screw until it

stops and, with the specific tool, tighten to the pre-
scribed torque.

Specific tooling
020055Y Wrench for steering tube ring nut

Locking torques (N*m)

Steering tube lower ring nut 14 ÷ 17

SUSP - 215
Suspensions Beverly 300 i.e.

- Fit the spacer between the two ring nuts on the

steering tube in the position indicated.

- Insert the upper tightening ring nut, screw until it

stops and, with the specific tool, tighten to the in-
dicated torque.

Specific tooling
020055Y Wrench for steering tube ring nut

Locking torques (N*m)

Steering tube upper ring nut 40 ÷ 45

SUSP - 216
Beverly 300 i.e. Suspensions

Insert the collar shown in the figure and restore the

cable passage as shown in the figure.

- Fit the front wheel.

Steering bearing

Removal

- Clean thoroughly and visually inspect if the com-

ponents are in good conditions.
- Check the upper steering bearing for wear.

- Check the lower steering bearing for wear.

SUSP - 217
Suspensions Beverly 300 i.e.

- Visually inspect that the steering fifth wheel

tracks, the headstock and the steering tube exhibit
no scores or abnormal wear. Otherwise, replace
them.
STEERING FIFTH WHEEL TRACK REMOVAL
- Remove the steering fifth wheel tracks on the
chassis with the specific tool, following the indica-
ted procedure.
- Fit the specific tool from the lower part of the
headstock until it makes contact with the upper
track.
- Hit with force the specific tool, placing it at differ-
ent points diametrically opposed so as to remove
the upper track.

Specific tooling
020004Y Punch for removing steering bearings
from headstock

- Repeat the procedure for the lower steering bearing track.

SUSP - 218
Beverly 300 i.e. Suspensions

- Remove the lower steering bearing seat on the

steering tube using the specific tool.

Specific tooling
020004Y Punch for removing steering bearings
from headstock

Refitting

STEERING FIFTH WHEEL TRACK FITTING

- Thoroughly clean the track seats on the head-
stock and the steering tube.
- Fit the new tracks of the headstock with the spe-
cific tool.
- Screw the nut until the tracks are fully inserted.
N.B.
LUBRICATE THE STEERING FIFTH WHEEL TRACKS WITH
RECOMMENDED GREASE BEFORE USE.

Specific tooling
001330Y Tool for fitting steering seats
001330Y014 Tool for fitting steering seats
001330Y015 Tool for fitting steering seats

Recommended products
AGIP GREASE PV2 Grease for steering bear-
ings, bolt seatings for swinging arms and fay-
ing surface of driven pulley spring (only pulley
side)
Soap-based lithium and zinc oxide grease con-
taining NLGI 2; ISO-L-XBCIB2

SUSP - 219
Suspensions Beverly 300 i.e.

- Fit the lower steering bearing seat on the steering

tube.
- With a tube of the indicated sizes, fit the lower
seat until it stops. Inside Ø: 35.5 mm; Outside Ø:
38 mm; Length: 350 mm.
N.B.
LUBRICATE THE STEERING FIFTH WHEEL TRACKS WITH
RECOMMENDED GREASE BEFORE USE.

Recommended products
AGIP GREASE PV2 Grease for steering bear-
ings, bolt seatings for swinging arms and fay-
ing surface of driven pulley spring (only pulley
side)
Soap-based lithium and zinc oxide grease con-
taining NLGI 2; ISO-L-XBCIB2

Rear

Removing the rear wheel

- Remove the silencer mounting bracket;

- Retrieve the conical spacer and remove the
wheel.

Refitting the rear wheel

- Carry out the removal operations but in reverse order, observing the prescribed tightening torques.

Locking torques (N*m)

Fixing screw for wheel rim to hub 33 - 37

Swing-arm

SUSP - 220
Beverly 300 i.e. Suspensions

Removal

- Place the vehicle on its centre stand;

- Support the engine adequately;
- Loosen the nut shown in the figure and pull out
the pin from the left-hand side.

- Loosen the nut and lock nut on the left-hand side

of the scooter (see figure) and unscrew the pin
from the opposite side.
- Remove the retaining screw of the rear brake
pipe shown in the figure.

- Loosen the nut on the inside of the frame from

the left-hand side (see figure) and remove the rel-
evant pin;
- Remove the swinging arm.

Overhaul

- Check that the silent bloc is not damaged. If there

is, replace it.
- Remove the Seeger ring shown in the picture

SUSP - 221
Suspensions Beverly 300 i.e.

- Remove the full silent bloc bracket

- Hold the full silent bloc bracket in the clamp
- Using the appropriate tool, remove the silent bloc
from the bracket from the side corresponding to
the inside of the vehicle. This is to guarantee the
tool is centred properly on the support

Specific tooling
020271Y Tool for removing-fitting silent bloc

- Install a new silent bloc, making sure it aligns

properly with the reference tooth.
- Fit the silent blocs, making sure the chamfered
part of the silent bloc matches the chamfered part
of the bracket

- Using the appropriate tool, fit the silent bloc as

shown in the picture

Specific tooling
020271Y Tool for removing-fitting silent bloc

SUSP - 222
Beverly 300 i.e. Suspensions

- Check there is no sticking in the movement of the

connection of the swinging arm on the engine side
to the swinging arm on the frame side.
- Check the axial clearance between the two
swinging arms using a feeler gauge

Characteristic
Allowable limit after use:
1 mm
standard clearance
0.40 ÷ 0.70 mm

- In order to check the clearance of the swinging

arm on the frame side, prepare a retainer using the
fixing pin of the swinging arm on the frame and two
rings from the special tool 020229Y.
Alternatively, use two washers with inside diame-
ter of 12 mm for pins, outside diameter min. 30 mm
and thickness min. 4 mm.

- Separate the swinging arm on the engine side

from the vehicle side arm.
- Remove the internal spacer shown in the picture

SUSP - 223
Suspensions Beverly 300 i.e.

- Using a suitable pin remove the roller casings as

shown in the pictures

- Using an appropriate tool plant new roller cas-

ings, being careful to position the bearings with the
O-rings facing outwards

Specific tooling
020115Y Ø 18 punch
020244Y 15-mm diameter punch

SWINGING ARM SERVICE

Specification Desc./Quantity
Length of the internal swinging arm spacer on the frame side 228 -0.2/-0.4 mm
Length of the internal swinging arm spacer on the engine side 183 0/-0.2 mm
Length of the swinging arm tube on the engine side 182.5 -0.1/-0.3 mm
Length of the swinging arm tube on the frame side 227.1+0.2/0 mm

- Lubricate the roller bearing housings with grease

- Insert the spacers
- Assemble the two arms with the relative bolt in
the position shown in the picture
- Adjust the bolt as shown in the picture
- Position the frame side swinging arm with the
most protruding part pointing towards the silent
block side as shown in the picture

Recommended products
AGIP GREASE PV2 Grease for control levers
on the engine
White anhydrous-calcium based grease to protect
roller bearings; temperature range between -20 °
C and +120 °C; NLGI 2; ISO-L-XBCIB2

SUSP - 224
Beverly 300 i.e. Suspensions

Refitting

In order to fit the swinging arm properly, follow

these steps:
- Position the silent block support bracket with part
«3 » pre-fitted and screw in but do not tighten part
«1».

- Position the swinging arm, inserting part « 2».

- Tighten part «3» to the prescribed torque.

- Screw and tighten part «4» to the prescribed tor-

que.

SUSP - 225
Suspensions Beverly 300 i.e.

- Screw and tighten part «5» to the prescribed tor-

que.

- Tighten part «1» to the prescribed torque.

- Insert the swinging arm - engine pin and tighten

to the prescribed torque.

SWINGING ARM FITTING

Name Torque in Nm
Part 1 64 - 72
Part 3 5-7
Part 4 90 - 110
Part 5 50 ÷ 55
Engine-swinging arm pin 55 ÷ 61

Shock absorbers

SUSP - 226
Beverly 300 i.e. Suspensions

Removal

Proceed as follows:
- place the vehicle on its centre stand;
- lift the engine a little with a jack so as to free the
two shock absorbers;
- remove the silencer
- undo the shock absorber spring assembly clamp-
ing screw from the support fixed to the engine on
the one side and from that fixed to the silencer on
the other;
- unscrew the two upper nuts (one on each side)
fixing the shock absorber spring assembly to the
frame and remove the shock absorbers.

See also
Exhaust assy. Removal

Refitting

Carry out the previous operations but in reverse order.

Locking torques (N*m)

Left shock absorber lower retainer 33 ÷ 41 Right shock absorber lower retainer 40 ÷ 45 Upper
shock absorber retainer 40 ÷ 45

Exhaust bracket

Removal

- Remove the silencer;

- Disconnect the connector from the speed sensor;

SUSP - 227
Suspensions Beverly 300 i.e.

- Unscrew the lower bolt fastening the right hand

shock absorber, remove the shock absorber from
its seat and retrieve the shim;

- Unscrew the screw indicated in the figure and re-

lease the rear brake hose from the silencer mount-
ing bracket;

- Unscrew the two bolts fastening the rear brake

calliper to the silencer mounting bracket;

- Unscrew the two screws fastening the rear mud-

guard indicated in the figure;

SUSP - 228
Beverly 300 i.e. Suspensions

- Working from the left hand side of the vehicle,

unscrew the two screws indicated and remove the
rear mudguard;

- Remove the safety split pin, aligning with the re-

cess on the bracket. Remove the nut cap;

- Undo the nut fastening the rear wheel;

- Unscrew the two screws fastening the silencer

mounting bracket to the engine, as indicated in the
figure, and remove the bracket.

See also
Exhaust assy. Removal

SUSP - 229
Suspensions Beverly 300 i.e.

Overhaul

- Remove the circlip shown in the picture

- Support the silencer support bracket sufficiently

- Using the special punch, remove the bearing
from its seat as shown in the picture

Specific tooling
020376Y Adaptor handle
020456Y Ø 24 mm adaptor

- Heat the bearing seat using the heat gun

- Using the special punch, install a new bearing in
the seat as shown in the picture

Specific tooling
020376Y Adaptor handle
020151Y Air heater

Refitting

To refit, carry out the removal operations in reverse order, observing the prescribed tightening torques.
N.B.

THE TIGHTENING MUFFLER MOUNTING ARM MUST BE TIGHTENED AFTER TIGHTENING THE
WHEEL.
Locking torques (N*m)
Rear wheel axle nut 104 to 126 Silencer supporting arm to engine screws (*) 20 to 25 Right shock
absorber lower retainer 40 ÷ 45

SUSP - 230
Beverly 300 i.e. Suspensions

Centre-stand

- Remove the two return springs from the centre

stand.
- Undo the nut shown in the figure.
- Remove the pin from the right side.
- Remove the centre stand.
- On refitting tighten the nut to the specified torque.

Locking torques (N*m)

Centre stand bolt 40 ÷ 45

Side stand

Removal of the side stand

- Unhook the springs;
- Loosen the nut;
- Pull out the screw;
Fitting
Carry out the previous operations but in reverse
order.

Locking torques (N*m)

Side stand fixing bolt 40 ÷ 45

SUSP - 231
INDEX OF TOPICS

BRAKING SYSTEM BRAK SYS

Beverly 300 i.e. Braking system

This section è is dedicated to the description of the braking system components.

Interventions rules
WARNING
BRAKING SYSTEM FLUID IS CORROSIVE: ALWAYS WEAR PROTECTIVE GLOVES. IN THE
EVENT OF ACCIDENTAL CONTACT WITH YOUR EYES, RINSE THE CONTACT AREA WELL
WITH ABUNDANT WATER.
THE BRAKE FLUID DRAINED FROM THE SYSTEM IS HARMFUL TO THE ENVIRONMENT. COL-
LECTION AND DISPOSAL MUST BE CARRIED OUT IN COMPLIANCE WITH THE REGULATIONS
IN FORCE. UNDER NORMAL DRIVING AND CLIMATIC CONDITIONS YOU SHOULD CHANGE
THE FLUID EVERY TWO YEARS. IF BRAKES ARE USED INTENSELY AND/OR IN HARSH CON-
DITIONS, CHANGE THE FLUID MORE FREQUENTLY.
DURING INSTALLATION, THE PARTS TO BE REUSED MUST BE ABSOLUTELY CLEAN AND
FREE FROM ANY TRACES OF OIL, FUEL AND GREASE: IT IS THEREFORE NECESSARY TO
CLEAN THEM THOROUGH WITH DENATURED ALCOHOL.
N.B.
FOR TOPPING UP AND CHANGE, USE ONLY BRAKE FLUID DOT4 - NHTSA 116.
OBSERVE THE MAXIMUM DEGREE OF CLEANLINESS. HYDRAULIC FLUID IS EXTREMELY
CORROSIVE FOR PAINTED SURFACES.
BRAKE FLUID IS HYGROSCOPIC; THAT IS, IT ABSORBS MOISTURE FROM THE SURROUND-
ING AIR.
IF THE MOISTURE CONTENT IN THE BRAKE FLUID EXCEEDS A CERTAIN VALUE, IT WILL RE-
SULT IN POOR BRAKING EFFICIENCY DUE TO A LOW BOILING POINT OF THE FLUID.
N.B.
ALWAYS USE FLUID FROM SEALED CONTAINERS.
N.B.
RUBBER PARTS SHOULD NEVER BE LEFT IN ALCOHOL LONGER THAN 20 SECONDS. AFTER
WASHING, THE PIECES MUST BE DRIED WITH A BLAST OF COMPRESSED AIR AND A CLEAN
CLOTH.
THE SEAL RINGS MUST BE IMMERSED IN THE OPERATING FLUID; THE USE OF PRF1 PRO-
TECTIVE DEVICE IS ALLOWED.
WARNING
THE PRESENCE OF BRAKE FLUID ON THE DISC OR BRAKE PADS REDUCES BRAKING EFFI-
CIENCY. IN THIS CASE, REPLACE THE PADS AND CLEAN THE DISC WITH A HIGH-QUALITY
SOLVENT.

Rear brake calliper

BRAK SYS - 233

Braking system Beverly 300 i.e.

Removal

- Remove the rear wheel.

- Remove the two rear brake calliper devices fas-
tening them to the support as shown in the picture.
N.B.
SHOULD THE BRAKE CALLIPER BE REPLACED, BEFORE
REMOVING THE FITTINGS FIXING THE CALLIPER TO THE
SUPPORTING BRACKET, FIRST LOOSEN THE OIL HOSE
FITTING AFTER HAVING EMPTIED THE SYSTEM OF THE
CIRCUIT BEING INSPECTED.

Refitting

- Follow the removal procedures but in reverse order and tighten to the prescribed torques with the
recommended product.

Recommended products
Loctite 243 Medium strength threadlock
Medium Loctite 243 threadlock

Locking torques (N*m)

Screw tightening calliper to support 20 to 25
If the calliper is replaced:
CAUTION
ONCE REFITTING IS FINISHED, BLEED THE SYSTEM.
CAUTION
ALWAYS USE NEW COPPER WASHERS.
Locking torques (N*m)
Rear brake calliper-pipe fitting 20 to 25
See also
Rear - combined

Front brake calliper

BRAK SYS - 234

Beverly 300 i.e. Braking system

Removal

- Remove the two retainers fastening the front

brake calliper to the support as shown in the pic-
ture.
N.B.
SHOULD IT BE NECESSARY TO REPLACE THE CALLIP-
ER, FIRST LOOSEN THE FITTING CONNECTING THE PIPE
TO THE BRAKE CALLIPER.

Refitting

- To fit the calliper, follow the above operations but in reverse order.

Locking torques (N*m)

Screw tightening calliper to support 24 ÷ 27
If the calliper is replaced:
CAUTION
ALWAYS USE NEW COPPER WASHERS.
CAUTION
ONCE REFITTING IS FINISHED, BLEED THE SYSTEM.
Locking torques (N*m)
Brake fluid pipe-calliper fitting 20 to 25
See also
Front

Rear brake disc

These vehicles may feature a rear wheel with integrated hub or with a hub independent from the wheel.

Removal

REAR WHEEL WITH INTEGRATED HUB

BRAK SYS - 235

Braking system Beverly 300 i.e.

- Remove the rear wheel.

- Act on the disc five fixing screws shown in the
picture.

See also
Removing the rear wheel

Refitting

REAR WHEEL WITH INTEGRATED HUB

For fitting, position the disc correctly using the ar-

row stamped on it as reference.
N.B.
THE ARROW STAMPED ON THE DISC INDICATING THE
RUNNING DIRECTION MUST BE FITTED TOWARDS THE
OUTSIDE OF THE VEHICLE.

- Tighten the screws to the prescribed torque and

apply the recommended product.

Recommended products
Loctite 243 Medium strength threadlock
Medium Loctite 243 threadlock

Locking torques (N*m)

Brake disc screws 8 to 10

BRAK SYS - 236

Beverly 300 i.e. Braking system

Disc Inspection

Checking the disc is important; it must be perfectly

clean, with no sign of rust, oil or grease or any oth-
er dirt, and must show no signs of deep scoring.

Characteristic
New rear disc thickness
4.0 mm
Disc thickness at wear limit (rear)
3.5 mm

- Using the specific tool, check that the axial run-

out of the brake surface is within the prescribed
limits.
- If this is not the case, replace the disc and repeat
the test.
WHEN INSTALLING, THOROUGHLY CLEAN THE DISC
AND ITS SEAT ON THE HUB.

Characteristic
Max. axial run-out
0.1 mm

Front brake disc

Removal

Proceed as follows:
- Remove the front wheel.
- Loosen the five disc fixing screws.
- Thoroughly clean the seats on the front wheel
hub and on the disc.

See also
Removing the front wheel

Refitting

For fitting, position the disc correctly using the arrow stamped on it as reference.
- Do up the screws to the prescribed torque and apply the recommended product

BRAK SYS - 237

Braking system Beverly 300 i.e.

N.B.
THE ARROW STAMPED ON THE DISC INDICATING THE RUNNING DIRECTION MUST BE FITTED
TOWARDS THE OUTSIDE OF THE VEHICLE.
Recommended products
Loctite 243 Medium strength threadlock
Medium Loctite 243 threadlock

Locking torques (N*m)

Brake disc screws 8 to 10

Disc Inspection

Checking the disc is important; it must be perfectly

clean, with no sign of rust, oil or grease or any oth-
er dirt, and must show no signs of deep scoring.

Characteristic
Thickness of a new front disc
4.0 mm
Disc thickness at wear limit (front)
3.5 mm

- Remove the wheel and check using the appro-

priate tools that the axial run-out of the brake
surface is within the prescribed limits.
- If this is not the case, replace the disc and repeat
the test.
WHEN INSTALLING, THOROUGHLY CLEAN THE DISC
AND ITS SEAT ON THE HUB.

Characteristic
Max. axial run-out
0.1 mm

Front brake pads

BRAK SYS - 238

Beverly 300 i.e. Braking system

Removal
Proceed as follows:
- Remove the front brake calliper.
- Loosen the two pins shown in the figure that lock
the two pads.
- Remove the pads, being careful with the pad
spring clamp.
- Check the thickness of the friction material of the
pads.
- Replace the pads if the thickness is below the
minimum value.
- The replacement must be made with greater re-
sidual thickness if the pad has not worn evenly. A
0.5 mm thickness difference in the residual friction
material is permitted.

Characteristic
Minimum value
1.5 mm

See also
Front
brake calliper

Refitting
To fit, proceed as follows:
- Insert the two pads in the callipers.
- Screw the two pad lock pins to the correct torque, and apply the recommended product.
- Fit the calliper on its support, tightening the two screws to the prescribed torque.
N.B.
IF IT IS NOT POSSIBLE TO CORRECTLY POSITION THE CALLIPER ON THE DISC DURING FIT-
TING, GENTLY EXPAND THE PADS.
Recommended products
Loctite 243 Medium strength threadlock

BRAK SYS - 239

Braking system Beverly 300 i.e.

Medium Loctite 243 threadlock

Locking torques (N*m)

Pad fastening pin 19.6 ÷ 24.5

Rear brake pads

Removal

- Remove the rear brake calliper

- Loosen the two pins shown in the figure that lock
the two pads; be careful with the pad spring clamp.
- Remove the brake pad and check there are no
faults or warping. Replace it if such anomalies are
present.
- Check the thickness of the friction material is
more than 1.5 mm. If it is not, replace it
- The replacement must be made with greater re-
sidual thickness if the pad has not worn evenly. A
0.5 mm thickness difference in the residual friction
material is permitted.

See also
Removal

BRAK SYS - 240

Beverly 300 i.e. Braking system

Refitting

To fit, proceed as follows:

- Insert the two pads in the callipers.
- Screw the two pad lock pins to the correct torque,
and apply the recommended product.
- Fit the calliper on its support, tightening the two
screws to the prescribed torque.
N.B.
IF IT IS NOT POSSIBLE TO CORRECTLY POSITION THE
CALLIPER ON THE DISC DURING FITTING, GENTLY EX-
PAND THE PADS.

Recommended products
Loctite 243 Medium strength threadlock
Medium Loctite 243 threadlock

Locking torques (N*m)

Screw tightening calliper to support 24 to 27 Pad
fastening pin 19.6 ÷ 24.5

Fill

Rear - combined

- Remove the rubber cap from the bleed screw.

- Insert a rubber pipe in the bleed screw to permit
the brake fluid to be recovered.
- With the brake lever, load the system and bring
it up to the required pressure.
- Keeping the brake lever pulled, loosen the bleed
screw to purge the air in the system. Then tighten
the bleed screw

- Repeat the operation until only brake fluid comes out of the rubber pipe.
- Remove the fluid recovery pipe and refit the rubber cap over the bleed screw.
- Top up the brake fluid to the right level in the reservoir.
If necessary, bleeding can be done using a special vacuum pump
N.B.
DURING THE BLEEDING OPERATIONS, MAKE SURE THE BRAKE FLUID DOES NOT COME INTO
CONTACT WITH THE BODYWORK SO AS NOT TO DAMAGE IT. FURTHERMORE, DURING THE
BLEEDING OPERATIONS REGARDING THE BRAKE CALLIPERS, MAKE SURE THE BRAKE
FLUID DOES NOT COME INTO CONTACT WITH THE DISC BRAKES AND WITH THE BRAKE
PADS. FAILURE TO OBSERVE THIS PRECAUTION WILL ENDANGER THE PROPER WORKING
AND EFFICIENCY OF THE BRAKING SYSTEM
Specific tooling

BRAK SYS - 241

Braking system Beverly 300 i.e.

020329Y Mity-Vac vacuum-operated pump

Locking torques (N*m)

System bleed calliper fitting: 12 ÷ 16 Nm

Front

- Remove the rubber cap from the bleed screw.

- Insert a rubber pipe in the bleed screw to permit
the brake fluid to be recovered.
- With the brake lever, load the system and bring
it up to the required pressure.
- Keeping the brake lever pulled, loosen the bleed
screw to purge the air in the system. Then tighten
the bleed screw

- Repeat the operation until only brake fluid comes out of the rubber pipe.
- Remove the fluid recovery pipe and refit the rubber cap over the bleed screw.
- Top up the brake fluid to the right level in the reservoir.
If necessary, bleeding can be done using a special vacuum pump
N.B.
DURING THE BLEEDING OPERATIONS, MAKE SURE THE BRAKE FLUID DOES NOT COME INTO
CONTACT WITH THE BODYWORK SO AS NOT TO DAMAGE IT. FURTHERMORE, DURING THE
BLEEDING OPERATIONS REGARDING THE BRAKE CALLIPERS, MAKE SURE THE BRAKE
FLUID DOES NOT COME INTO CONTACT WITH THE DISC BRAKES AND WITH THE BRAKE
PADS. FAILURE TO OBSERVE THIS PRECAUTION WILL ENDANGER THE PROPER WORKING
AND EFFICIENCY OF THE BRAKING SYSTEM
Specific tooling
020329Y Mity-Vac vacuum-operated pump

Locking torques (N*m)

System bleed calliper fitting: 12 ÷ 16 Nm

Brake fluid level check

The front and rear brake fluid reservoirs are both

positioned on the handlebar. Proceed as follows:
- Rest the vehicle onto the centre stand, with the
handlebar centred.
- Check the fluid level through the sight glass
«A».
A certain lowering of the level is caused by wear
on the brake pads.

BRAK SYS - 242

Beverly 300 i.e. Braking system

Front brake pump

Removal

- Remove the rear handlebar cover.

- Drain the braking system.
- Disconnect the brake fluid line from the pump,
paying attention to a possible escape of remaining
brake fluid.
- Remove the brake stop button from the lever.
- Undo the two U-bolt fixing screws.
- Remove the brake pump with the lever.

Refitting

- Upon refitting, perform the operation but in reverse order.

- Tighten the hydraulic line to the prescribed torque and purge the system.
- When the operation is over, tighten the brake fluid bleed screw to the prescribed torque.
N.B.
WHILE REFITTING, REPLACE THE COPPER GASKETS ON THEIR FITTINGS.
WARNING
BRAKE FLUID IS HYGROSCOPIC; THAT IS, IT ABSORBS MOISTURE FROM THE SURROUND-
ING AIR. IF THE LEVEL OF MOISTURE IN THE FLUID EXCEEDS A GIVEN VALUE, BRAKING WILL
BE INEFFICIENT. THEREFORE, ALWAYS USE FLUID FROM SEALED CONTAINERS. UNDER
NORMAL DRIVING AND CLIMATIC CONDITIONS YOU SHOULD CHANGE THIS FLUID EVERY
TWO YEARS. IF BRAKES ARE USED INTENSELY AND/OR IN HARSH CONDITIONS, CHANGE
THE FLUID MORE FREQUENTLY.
CAUTION
WHEN CARRYING OUT THE OPERATION, BRAKE FLUID MAY LEAK FROM BETWEEN THE
BLEED SCREW AND ITS SEAT ON THE CALLIPER. CAREFULLY DRY THE CALLIPER AND DE-
GREASE THE DISC SHOULD THERE BE BRAKE FLUID ON IT.
Locking torques (N*m)
Oil bleed screw 12 - 16 Hydraulic line fixing screw: 16 - 20 Fixing screws for the handlebar control
unit U-bolts 7 to 10
See also
Front

Rear brake pump - combined

BRAK SYS - 243

Braking system Beverly 300 i.e.

Removal

- Remove the rear handlebar cover.

- Drain the braking system.
- Disconnect the brake fluid line from the pump,
paying attention to a possible escape of remaining
brake fluid.
- Remove the brake stop button from the lever.
- Undo the two U-bolt fixing screws.
- Remove the brake pump with the lever.

Refitting

- Upon refitting, perform the operation but in reverse order.

- Tighten the hydraulic line to the prescribed torque and purge the system.
- When the operation is over, tighten the brake fluid bleed screw to the prescribed torque.
N.B.
WHILE REFITTING, REPLACE THE COPPER GASKETS ON THEIR FITTINGS.
WARNING
BRAKE FLUID IS HYGROSCOPIC; THAT IS, IT ABSORBS MOISTURE FROM THE SURROUND-
ING AIR. IF THE LEVEL OF MOISTURE IN THE FLUID EXCEEDS A GIVEN VALUE, BRAKING WILL
BE INEFFICIENT. THEREFORE, ALWAYS USE FLUID FROM SEALED CONTAINERS. UNDER
NORMAL DRIVING AND CLIMATIC CONDITIONS YOU SHOULD CHANGE THIS FLUID EVERY
TWO YEARS. IF BRAKES ARE USED INTENSELY AND/OR IN HARSH CONDITIONS, CHANGE
THE FLUID MORE FREQUENTLY.
CAUTION
WHEN CARRYING OUT THE OPERATION, BRAKE FLUID MAY LEAK FROM BETWEEN THE
BLEED SCREW AND ITS SEAT ON THE CALLIPER. CAREFULLY DRY THE CALLIPER AND DE-
GREASE THE DISC SHOULD THERE BE BRAKE FLUID ON IT.
Locking torques (N*m)
Oil bleed screw 12 - 16 Hydraulic line fixing screw: 16 - 20 Fixing screws for the handlebar control
unit U-bolts 7 to 10
See also
Rear - combined

BRAK SYS - 244

INDEX OF TOPICS

COOLING SYSTEM COOL SYS

Cooling system Beverly 300 i.e.

Circuit diagram

KEY
A = Expansion tank
B = Radiator
C = Radiator intake pipe

COOL SYS - 246

Beverly 300 i.e. Cooling system

D = Water pump
E = Delivery pipe to cylinder
F = By-Pass pipe
G = Thermostat
H = Radiator delivery pipe

TECHNICAL SPECIFICATIONS
Specification Desc./Quantity
Cooling system capacity: ~2l
Recommended fluid AGIP PERMANENT SPEZIAL (ready for use)
Sealing pressure Cap calibrated at 0.9 bar

THERMOSTAT
Specification Desc./Quantity
Type Wax-type, with deviator
Starts opening at 85 ± 2°C

ELECTRIC VENTILATION
Specification Desc./Quantity
Electric ventilation starts at 100° C
Electric ventilation stops at 90° C

WATER PUMP
Specification Desc./Quantity
Type Centrifugal
Control Electric, commanded by the control unit

RADIATOR
Specification Desc./Quantity
Type Aluminium, with horizontal circulation

EXPANSION TANK
Specification Desc./Quantity
Calibration Automatic bleeding, in parallel with the radiator

Electric fan check

- Check and, if necessary, restore the correct battery voltage.

Characteristic
Battery voltage
12V

COOL SYS - 247

Cooling system Beverly 300 i.e.

- Check that the electric ventilation relay is working

properly.

WARNING
TO INDICATE THE SOLENOID OF THE DESIRED FUNCTION, REFER TO THE PIN-CABLE COL-
OUR RELATIONSHIP WITH THE ATTACHED ELECTRIC SYSTEM DIAGRAM.
- If the relay is not working, replace it.
- If the relay is working, remove it and jump the red
- red black (85 - 86) wires. The electric ventilation
starts if the ignition switch is set to «ON» and all
components are working.

- In order to check the coolant temperature sensor, see the «Injection» chapter.

See also
Remote controls check

System bleed

- Start up the engine until the operating tempera-

ture is reached.
- Remove the rubber hood over the bleed valve
- Obtain a rubber tube that is of the right length to
connect the valve to the expansion tank
- Place one end of the pipe on the bleed valve and
the other in the expansion tank
- Loosen the screw by two turns until the commu-
nication hole is revealed with the head as shown
in the picture
- Wait until only coolant comes out of the rubber
pipe so as to eliminate any air bubbles inside the
circuit.

COOL SYS - 248

Beverly 300 i.e. Cooling system

- Tighten the bleed valve respecting the maximum

torque.
- Bring the coolant up to the correct level inside the
expansion tank

Locking torques (N*m)

Bleed screw 3

Thermostat

Removal

- Remove the helmet compartment inspection cov-

er.
- Place a + 2.0 l container under the vehicle to col-
lect the coolant.
- Undo the two screws indicated, lift the cover and
remove the thermostat.

COOL SYS - 249

Cooling system Beverly 300 i.e.

Check

1) Visually inspect that the thermostat is not dam-

aged.
2) Fill a metal container with approx. 1 litre of wa-
ter.
Immerse the thermostat, and keep it in the centre
of the container.
Immerse the multimeter temperature probe, and
keep it close to the thermostat.
Heat up the container using the thermal gun.
Check the temperature at which the thermostat
starts to open:
Heat up until the thermostat is completely open.
3) Replace the thermostat if it is not working prop-
erly.
CAUTION
TO EXECUTE THE TEST CORRECTLY, MAKE SURE NEI-
THER THE THERMOSTAT NOR THE THERMOMETER
TOUCHES THE CONTAINER.

Specific tooling
020331Y Digital multimeter
020151Y Air heater

THERMOSTAT
Specification Desc./Quantity
Type Wax-type, with deviator
Starts opening at 85±2°C

Refitting

- Follow the removal steps but in reverse order; be careful to tighten screws to the prescribed torque.

Locking torques (N*m)

Thermostat cover screws 3 to 4
- Once the cooling circuit is restored, refill using the recommended product and purge the circuit as
expressly indicated in the «Cooling System» chapter.

COOL SYS - 250

INDEX OF TOPICS

CHASSIS CHAS
Chassis Beverly 300 i.e.

This section è is dedicated to the operations that can be carried out on the vehicle's bodywork.

Seat

Undo the two screws indicated in the figure and

retrieve the two bushings.

Rear rack

To remove the luggage rack:

- Lift the saddle;
- Unscrew the indicated screw and remove the
plastic cover;

- Unscrew the two indicated screws and retrieve

the washers;

CHAS - 252
Beverly 300 i.e. Chassis

- Unscrew the centre screw and retrieve the wash-

ers;
- Remove the luggage rack.

Rear handlebar cover

To remove the handlebar cover, proceed as fol-

lows:
- Remove the mirrors unscrewing them from their
seats
- Unscrew the two screws «A» and remove the
pressure covering.
- Unscrew the two screws «B» and, working on
both sides of the vehicle, unscrew the screw «C».
- Using a flat-headed screwdriver, detach the fas-
tener tab as shown in the figure, accessing the tab
via the indicated slit
- Insert the screwdriver between the two covers,
as indicated in the figure, and detach the upper
fastener tab
- Move the rear handlebar cover aside, disconnect
all the electrical connectors and remove the han-
dlebar cover.

CHAS - 253
Chassis Beverly 300 i.e.

CHAS - 254
Beverly 300 i.e. Chassis

Instrument panel

- Remove the rear handlebar cover;

- Undo the fours screws indicated to remove the
assembly.

Front handlebar cover

To remove the handlebar cover, proceed as fol-

lows:
- Remove the rear handlebar cover.
- Unscrew the two screws «D» and remove the
front handlebar cover, disconnecting the front
headlight connector

See also
Rear handlebar cover

Headlight assy.

Frame central cover

- Remove the side fairings;

- Remove the footrests;
- Open the glove compartment and undo the four
screws indicated on both sides of the vehicle;

CHAS - 255
Chassis Beverly 300 i.e.

- Undo the indicated screw on both sides of the

vehicle;
- Release the fastener clips and remove the cover;

- Undo the two screws indicated on both sides of

the vehicle;
- Lift the rear of the cover to access the clamp fas-
tening the bellow to the fuel tank, and detach the
clamp with a screwdriver;
- Remove the central frame cover.

Legshield

To remove the front shield, proceed as follows:

- Remove the frame central cover;
- Undo the indicated screw on both sides of the
vehicle;

CHAS - 256
Beverly 300 i.e. Chassis

- Remove the Piaggio clip-on badge and undo the

screw underneath;

- Undo the two screws indicated and remove the

expansion tank cover.
- Undo the indicated screw;

CHAS - 257
Chassis Beverly 300 i.e.

- Open the glove compartment and undo the indi-

cated screw from both sides of the vehicle.
- Move the shield aside, releasing the fastener
clips, and disconnect the connectors and lamp
holders from the headlights;
- Unscrew the three screws indicated to remove
the two headlights from the shield.

See also
Frame central cover

Knee-guard

To remove the leg shield back plate, proceed as

follows:
- Remove the legshield;
- Unscrew the expansion tank cap;
- Unscrew the two screws indicated and release
the two retainer tabs to remove the indicated cov-
er;

- Unscrew the screw located above the emergency

saddle release lever and the screw near the igni-
tion key;

CHAS - 258
Beverly 300 i.e. Chassis

- Undo the two screws indicated in the figure;

- Disconnect the LV socket connector and the

coolant return pipe from the relative seat on the leg
shield back plate;
- Unscrew the screw fastening the expansion tank
to the leg shield back plate, taking care not to spill
any coolant;

- Detach the emergency saddle release linkage

from the lever as indicated in the figure;
- Remove the leg shield back plate.

See also
Legshield

CHAS - 259
Chassis Beverly 300 i.e.

Removing the ignition key-switch when on *off*

Proceed as follows to remove the lock when in the

«OFF» position:
- Remove the leg shield back plate;
- Disconnect the connector as indicated in the fig-
ure and remove the immobilizer antenna, detach-
ing from the lock body;

- Release the indicated clip and remove the igni-

tion key;

- Press the lock body and remove the cylinder clip

as indicated;
- Release the lock body and remove the cylinder.

See also
Knee-guard

CHAS - 260
Beverly 300 i.e. Chassis

Removing the ignition key-switch when on *lock*

In position "Lock", it is not possible to access the

cylinder retaining spring. The spring must then be
removed as shown in the figure, allowing the lock
spring to be pressed out.
N.B.
TO REFIT THIS ITEM, THE VEHICLE STEERING LOCK
MUST BE RELEASED WITH THE LOCK BODY (INTERNAL
AND EXTERNAL PART) IN POSITION "OFF". PROCEED AS
DESCRIBED IN THE PREVIOUS PARAGRAPH.

See also
Removing the ignition key-switch when on *off*

Front wheel housing

To remove the front wheel housing, proceed as

follows:
- Remove the leg shield back plate;
- Remove the handlebar covers;
- Remove the fork;
- Release the indicated clamps from the wheel
housing;
- Undo the three screws indicated and remove the
wheel housing.

See also
Knee-guard

CHAS - 261
Chassis Beverly 300 i.e.

Taillight assy.

To remove the rear light assembly, proceed as fol-

lows:
- Remove the side fairings;
- Undo the three screws indicated in the figure.

See also
Side fairings

Footrest

The following procedure is applicable for both

sides of the vehicle:
- Unscrew the three screws indicated and remove
the passenger footrest;

- Unscrew the screw fastening the footrest to the

side fairing;

CHAS - 262
Beverly 300 i.e. Chassis

- Unscrew the screws fastening the footrest to the

front wheel housing;

- Use a flat headed screwdriver to remove the

plugs and the mat as indicated in the figure;
- Unscrew the three screws indicated and remove
the passenger footrest, releasing the fastener
clips.

Side fairings

Proceed as follows to remove the side fairings:

- Remove the saddle;
- Remove the rear luggage rack;
- Unscrew the two screws indicated and remove
the centre rear cover;

CHAS - 263
Chassis Beverly 300 i.e.

- Unscrew the screw fastening the taillight;

- Unscrew the screw indicated in the figure;

- Unscrew the three screws indicated and remove

the side fairing, complete with taillights, releasing
the indicated fastener clip. Disconnect the two
connectors from the taillight.

See also
Seat

CHAS - 264
Beverly 300 i.e. Chassis

License plate holder

To remove the license plate mounting, proceed as

follows:
- Remove the helmet compartment;
- Undo the three screws indicated;
- Unscrew the indicated screw and release the li-
cense plate light lamp holder.

See also
Helmet bay

Helmet bay

To remove the helmet compartment, proceed as

follows:
- Remove the side fairings;
- Pull out the battery cables and unscrew the screw
«A» and «B»;

CHAS - 265
Chassis Beverly 300 i.e.

- Unscrew the two screws indicated to release the

lock and detach the lock linkages from the indica-
ted retainer in the compartment itself;

- Unscrew the two rear screws;

- Undo the indicated screw on both sides of the

vehicle;

CHAS - 266
Beverly 300 i.e. Chassis

- Unscrew the two screws indicated;

- Lift the rear of the helmet compartment, discon-

nect the helmet compartment light connector and
release the saddle release linkage retainer clip;
- Remove the helmet compartment, detaching
from the fuse terminal block.

See also
Side fairings

Front mudguard

To remove the front mudguard, proceed as fol-

lows:
- On both sides of the vehicle, unscrew the indica-
ted screws and remove the stanchion guard;

CHAS - 267
Chassis Beverly 300 i.e.

- Unscrew the three bolts indicated inside the mud-

guard;
- Detach the brake hose from the two indicated
seats and remove the mudguard, pulling from the
front.

Radiator fan

To remove the radiator electric fan, proceed as

follows:
- Remove the front wheel housing.
- Obtain a suitably sized container and drain the
cooling system by removing the indicated clamp.
Open the expansion tank cap to facilitate draining;

- Detach the radiator from the circuit pipes;

- Unscrew the indicated screw and remove the ra-
diator, lifting out of its seat.

See also
Front wheel housing

CHAS - 268
Beverly 300 i.e. Chassis

Expansion tank

To remove the expansion tank, proceed as fol-

lows:
- Remove the leg shield back plate;
- Drain the cooling system by removing the indi-
cated clamp;
- Unscrew the indicated screw and remove the ex-
pansion tank.

See also
Knee-guard

Battery

To access the battery, proceed as follows:

- Position the vehicle on centre stand
- Open the saddle, following the previously descri-
bed procedure
- Unscrew the three screws «A» and remove the
cover «B»
The battery is the electrical device that requires the
most frequent attention and the most thorough
maintenance.
The main points of maintenance to be observed
are as follows:
WARNING

DO NOT DISCONNECT THE BATTERY CABLES WITH THE

ENGINE RUNNING, THIS CAN CAUSE IRREPARABLE
DAMAGE TO THE VEHICLE'S ELECTRONIC CONTROL
UNIT.

CHAS - 269
Chassis Beverly 300 i.e.

WARNING

USED BATTERIES ARE HARMFUL FOR THE ENVIRON-

MENT. COLLECTION AND DISPOSAL SHOULD BE CAR-
RIED OUT IN COMPLIANCE WITH REGULATIONS IN
FORCE.

Characteristic
Battery
SEALED 12V/10Ah

CHAS - 270
INDEX OF TOPICS

PRE-DELIVERY PRE DE
Pre-delivery Beverly 300 i.e.

Carry out the listed tests before delivering the vehicle.

Warning - Handle fuel with care.

Aesthetic inspection

Appearance check:
- Paintwork
- Fitting of plastics
- Scratches
- Dirt

Tightening torques inspection

- Visually check that there is a yellow mark on the following clamps:

FRONT SUSPENSION
• Front wheel pin nut.
• Screws fixing wheel pin on right fork leg.

FRONT BRAKE
• Screws fixing front brake callipers to fork.
• Brake pipes / front brake calliper coupling.

REAR SUSPENSION
• Rear wheel tightening screws.
• Lower shock absorber retainer.
• Nuts fixing muffler supporting arm - engine.
• Screws fixing muffler to supporting arm.
• Rear wheel pin nut.

REAR BRAKE
• Screws fixing rear brake calliper to supporting plate.
• Brake pipe to rear brake calliper coupling.
• Screws fixing supporting plate to engine.

Electrical system

• Main switch
• Lights: high-beam lights, low-beam lights, taillights (front and rear) and relevant warning lights
- Headlight adjustment according to the regulations currently in force
• Front and rear stop light buttons and relative light •Turn indicators and relative telltales
• Instrument lighting
• instruments: fuel and temperature indicator

PRE DE - 272
Beverly 300 i.e. Pre-delivery

•Instrument panel lights

• Horn
• Electrical start up
• Engine stopping with emergency stop switch
• electric saddle opening button
CAUTION
TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE.
INADEQUATE CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFORE
IT IS FIRST USED SHORTENS 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 YOUR EYES, SKIN AND CLOTHING.
IN CASE OF CONTACT WITH YOUR EYES OR SKIN, RINSE WITH ABUNDANT WATER FOR
ABOUT 15 MINUTES AND SEEK IMMEDIATE MEDICAL ATTENTION.
IF IT ACCIDENTALLY SWALLOWED, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR
VEGETABLE OIL. SEEK IMMEDIATE MEDICAL ATTENTION.
BATTERIES PRODUCE EXPLOSIVE GASES; KEEP THEM AWAY FROM NAKED FLAMES,
SPARKS AND CIGARETTES. IF THE BATTERY IS CHARGED IN A CLOSED PLACE, TAKE CARE
TO ENSURE ADEQUATE VENTILATION. ALWAYS PROTECT YOUR EYES WHEN WORKING
CLOSE TO 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.

Levels check

Level check:
- Hydraulic brake system liquid level.
- Rear hub oil level
- Engine coolant level
- Engine oil level

Road test

Test ride
- Cold start
- Instrument operations
- Response to the throttle control
- Stability on acceleration and braking
- Rear and front brake efficiency
- Rear and front suspension efficiency

PRE DE - 273
Pre-delivery Beverly 300 i.e.

- Abnormal noise

Static test

Static control after the test ride:

• Hot engine restart
• Minimum seal (turning the handlebar)
• Uniform steering rotation
• Possible losses
• electric radiator fan operation
CAUTION
CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE.
CAUTION
NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES OR TYRES MAY BURST.

Functional inspection

Functional Checks:
• Hydraulic braking system: lever travel
• Clutch: proper functioning check
• Engine: proper general functioning and no abnormal noise check
• Other: papers check, frame and engine number check, tools and equipment, licence plate fitting, lock
check, tyre pressure check, rear-view mirror and any accessory fitting

Instruments start-up

Use the switch "MODE" to "ODO" mode

Hold the switch "MODE" for more than 3 seconds,
the hours will be displayed. Hours will increase
each time the "MODE" button is pressed.
Once the hour is adjusted, hold the switch "MODE"
more than 3 seconds to display the minutes. Mi-
nutes will increase each time the "MODE" button
is pressed.
If no key is pressed for 3 seconds, the system will
leave the clock adjustment mode.
WARNING
FOR SAFETY REASONS, CLOCK ADJUSTMENT IS POSSI-
BLE EXCLUSIVELY WITH VEHICLE SPEED EQUAL TO 0
Km/h.

PRE DE - 274
Beverly 300 i.e. Pre-delivery

TRIP COUNTER PARTIAL RESET

In the partial trip counter function, press and hold
the MODE button for longer than 3 seconds and it
will reset.

SELECT MILES - KM
When using the function measuring the voltage of
the battery, holding down the MODE button for
longer than 10 seconds will switch between read-
ing in kilometres or miles for the odometer.
For the first 5 seconds, the instrument panel will
not give any signal; for the next 5 seconds the unit
of measurement (km or miles) currently in use will
be displayed blinking at frequency of 1 Hz. If the
button is released before 10 seconds, the unit of
measurement will not be changed.

PRE DE - 275
INDEX OF TOPICS

TIME TIME
Beverly 300 i.e. Time

This section is dedicated to the time necessary to carry out repairs.

For each operation, the description, code and time envisages are specified.

Engine

ENGINE
Code Action Duration
1 001001 Engine from chassis - Removal and
refit.
2 003064 Engine oil - change
3 001127 Engine - Complete service

TIME - 277
Time Beverly 300 i.e.

Crankcase

CRANKCASE
Code Action Duration
1 001153 Crankcase halves gasket - Replace-
ment
2 001133 Engine crankcase - Replacement
3 001124 Lubrication by pass - Replacement

TIME - 278
Beverly 300 i.e. Time

Crankshaft

CRANKSHAFT
Code Action Duration
1 001117 Crankshaft - Replacement

TIME - 279
Time Beverly 300 i.e.

Cylinder assy.

CYLINDER - PISTON
Code Action Duration
1 001002 Cylinder / Piston - Replacement
2 001154 Pistonsrings-pin assembly - Service
3 001176 Rings / Pin - Replacement

TIME - 280
Beverly 300 i.e. Time

Cylinder head assy.

VALVE HEAD
Code Action Duration
1 001126 Head - Replacement
2 001045 Valves - Replacement
3 001049 Valves - adjust
4 001056 Head gasket - change
5 000235 Coolant temperature sensor - Repl.
6 001057 Thermostat - Replacement
7 007012 Coolant bleed valve - Replacement

TIME - 281
Time Beverly 300 i.e.

Rocker arms support assy.

CAMSHAFT
Code Action Duration
1 001148 Rockers valves - Replacement
2 001044 Camshaft - Replacement
3 001169 Pressure reducer - Replacement

TIME - 282
Beverly 300 i.e. Time

Cylinder head cover

HEAD COVER
Code Action Duration
1 001093 Spark plug - Replacement
2 001089 Head cover - Replacement
3 001088 Head cover gasket - Replacement
4 001074 Oil vapour recovery pipe - Replace-
ment

TIME - 283
Time Beverly 300 i.e.

Oil filter

OIL FILTER
Code Action Duration
1 001123 Oil filter -Replacement
2 001160 Oil pressure sensor - change
3 001102 Net oil filter - change / Cleaning

TIME - 284
Beverly 300 i.e. Time

Flywheel cover

FLYWHEEL COVER
Code Action Duration
1 001087 Flywheel cover - Replacement
2 001150 Flywheel cover gasket - change
3 007007 Water pump rotor - Replacement
4 001113 Water pump / Pump rotor - Replace-
ment
5 001099 Flywheel-side oil seal - Replacement

TIME - 285
Time Beverly 300 i.e.

Driven pulley

DRIVEN PULLEY
Code Action Duration
1 001022 Clutch - Replacement
2 001012 Driven pulley - overhaul
3 001110 Driven pulley- Replacement
4 001155 Clutch housing - Replacement

TIME - 286
Beverly 300 i.e. Time

Oil pump

OIL PUMP
Code Action Duration
1 001125 Chain guide pads - Replacement
2 001051 Distribution belt - Timing chain - Re-
placement
3 001042 Oil pump - overhaul
4 001112 Oil pump - change
5 001122 Oil pump chain - Replacement
6 001172 Chain cover flap - change
7 001130 Oil sump - change
8 001129 Chain tensioner - Service and Re-
placement
9 888133 Chain cover flap - Check / replace-
ment

TIME - 287
Time Beverly 300 i.e.

Final gear assy.

FINAL REDUCTION GEAR

Code Action Duration
1 001010 Reduction gear - Replacement
2 003065 Gear box oil - Replacement
3 001156 Reduction gear cover - Replacement
4 004125 Rear wheel axle - Replacement
5 004180 Reduction gear pipe - replace

TIME - 288
Beverly 300 i.e. Time

Driving pulley

DRIVING PULLEY
Code Action Duration
1 001086 Driving half-pulley - Replacement
2 001011 Drive belt - Replacement
3 001066 Driving pulley - Removal and refitting
4 001177 CVT rollers / sliders - Replacement
5 001141 Belt anti-flapping roller - Replace-
ment
6 001006 Driving pulley - Service
7 001175 Anti-flapping roller/ Belt - Service

TIME - 289
Time Beverly 300 i.e.

Transmission cover

TRANSMISSION COVER
Code Action Duration
1 001096 Transmission crankcase cover - Re-
placement
2 001135 Transmission cover bearing - Re-
placement
3 001170 Air deflector - Replacement

TIME - 290
Beverly 300 i.e. Time

Water pump

WATER PUMP
Code Action Duration
1 007017 Water pump cover - Replacement
2 007009 Head-pump by-pass rubber sleeve -
Replacement

TIME - 291
Time Beverly 300 i.e.

Starter motor

ELECTRIC STARTER
Code Action Duration
1 001020 Starter motor - Replacement
2 001151 Starter driven gearing - Replacement
3 001017 Start-up pinion - Replacement

TIME - 292
Beverly 300 i.e. Time

Flywheel magneto

MAGNETO FLYWHEEL
Code Action Duration
1 001067 Stator - Removal and Refitting
2 001173 Rotor - Replacement
3 001058 Complete flywheel - change
4 001104 Start-up freewheel - Replacement

TIME - 293
Time Beverly 300 i.e.

Butterfly valve

THROTTLE BODY
Code Action Duration
1 001166 Throttle body - Replacement
2 001047 Injector - Replacement
3 001013 Intake manifold - change

TIME - 294
Beverly 300 i.e. Time

Exhaust pipe

MUFFLER
Code Action Duration
1 005138 Lambda probe - Replacement
2 001092 Exhaust manifold - Replacement
3 001095 Silencer heatshield - Replacement
4 001009 Silencer - Replacement

TIME - 295
Time Beverly 300 i.e.

Air cleaner

AIR CLEANER
Code Action Duration
1 001015 Air filter box - Replacement
2 001014 Air filter - Replacement / cleaning
3 004122 Air cleaner/ carburettor union - Re-
placement

TIME - 296
Beverly 300 i.e. Time

Frame

CHASSIS
Code Action Duration
1 004001 Chassis - Replacement
2 004147 footboard support bracket one side -
Replacement
3 004148 Footrest support bracket, both sides
- Replacement
4 004146 Front chassis - Replacement

TIME - 297
Time Beverly 300 i.e.

Centre-stand

STAND
Code Action Duration
1 001053 Stand pin - Replacement
2 004004 Stand - Replacement
3 004179 Stand bumper - Replacement
4 004102 Side stand - Replacement
5 005079 Stand switch - Replacement

TIME - 298
Beverly 300 i.e. Time

Legshield spoiler

LEGSHIELD - SPOILER
Code Action Duration
1 004064 Legshield, front section - Replace-
ment
2 004023 Shield rim - Replacement
3 004149 shield central cover - Replacement

TIME - 299
Time Beverly 300 i.e.

Side fairings

SIDE COVERS
Code Action Duration
1 004012 Rear side panels - Replacement
2 004129 Rear fairing - Replacement

TIME - 300
Beverly 300 i.e. Time

Rear cover

REAR SHIELD
Code Action Duration
1 004065 Shield back plate - Replacement
2 004081 Top box lid - Replacement

TIME - 301
Time Beverly 300 i.e.

Central cover

CENTRAL COVER
Code Action Duration
1 004135 Fuel tank port - Replacement
2 004011 Central chassis cover - Replacement
3 004059 Spark plug inspection flap - Replace-
ment
4 004015 Footrest - Replacement

TIME - 302
Beverly 300 i.e. Time

Underseat compartment

HELMET COMPARTMENT
Code Action Duration
1 004106 Helmet compartment band - Re-
placement
2 005033 Glove-box light switch - Replace-
ment
3 004016 Helmet compartment - Replacement
4 004112 Cock / carburettor hose - Replace-
ment
5 005046 Battery cover - change
6 005026 Helmet compartment bulb - Replace-
ment

TIME - 303
Time Beverly 300 i.e.

Plate holder

LICENSE PLATE HOLDER

Code Action Duration
1 004136 License plate holder mounting - Re-
placement
2 005048 number plate holder - Replacement

TIME - 304
Beverly 300 i.e. Time

Mudguard

MUDGUARDS
Code Action Duration
1 004002 Front mudguard - change
2 004053 Spoiler - Replacement
3 004009 Rear mudguard - Replacement

TIME - 305
Time Beverly 300 i.e.

Fuel tank

FUEL TANK
Code Action Duration
1 004109 Fuel tank breather - change
2 004005 Fuel tank - Replacement
3 005010 Tank float - Replacement

TIME - 306
Beverly 300 i.e. Time

Rear shock-absorber

REAR SHOCK ABSORBER

Code Action Duration
1 003077 Muffler supporting arm/ rear shock
absorber - Replacement
2 003007 Rear shock absorber - Replacement

TIME - 307
Time Beverly 300 i.e.

Handlebar covers

HANDLEBAR COVERS
Code Action Duration
1 004018 Front handlebar covers - Replace-
ment
2 004019 Rear handlebar covers - Replace-
ment

TIME - 308
Beverly 300 i.e. Time

Handlebar components

HANDLEBAR COMPONENTS
Code Action Duration
1 002060 Complete throttle control - Replace-
ment
2 002059 Right-hand knob - Replacement

TIME - 309
Time Beverly 300 i.e.

Code Action Duration

3 003001 Handlebar - Replacement
4 003061 Accelerator transmission - adjust
5 002063 Complete throttle transmission - Re-
placement
6 002071 Left knob - Replacement
7 002037 Brake lever - Replacement
8 002067 Rear brake pump - Replacement
9 002024 Front brake pump - Replacement
10 004162 Mirror mounting and/or brake pump
fitting U-bolt - Replacement
11 004066 Driving mirror - Replacement

Swing-arm

SWINGING ARM
Code Action Duration
1 003080 Swinging arm on frame - Replace-
ment
2 001072 Engine/chassis swinging arm attach-
ment - Replacement
3 004058 Silent block - Replacement
4 003081 Swinging arm support flange - Re-
placement

TIME - 310
Beverly 300 i.e. Time

Brake hoses

BRAKE PIPING
Code Action Duration
1 002021 Front brake piping - Replacement
2 003070 Front brake pads/shoes - Check for
wear
3 002007 Front brake pads - Replacement
4 002039 Front brake calliper - Replacement
5 002047 Front brake fluid and air bleed sys-
tem - Replacement
6 002020 Rear brake disc piping - Replace-
ment
7 002081 Rear brake rigid pipes - Replacement
8 003071 Rear brake pads/shoes - Check for
wear
9 002002 Rear brake pads - Replacement
10 002080 Rear brake oil bleed system -
Change
11 002048 Rear brake calliper - Replacement

TIME - 311
Time Beverly 300 i.e.

Seat

SADDLE
Code Action Duration
1 004003 Saddle - Replacement
2 004144 Saddle cover - Replacement

TIME - 312
Beverly 300 i.e. Time

Instrument panel

INSTRUMENT PANEL
Code Action Duration
1 005014 Odometer - Replacement
2 005078 Odometer glass - Replacement
3 005038 Dashboard warning/telltale lights -
Replacement
4 005076 Clock / Cell - Replacement

TIME - 313
Time Beverly 300 i.e.

Rear rack

LUGGAGE RACK
Code Action Duration
1 004008 Luggage rack - Replacement
2 004062 Luggage rack cover - Replacement

TIME - 314
Beverly 300 i.e. Time

Locks

LOCKS
Code Action Duration
1 004010 Anti-theft lock - Replacement
2 004054 Saddle lock catch - Replacement
3 005099 Electric saddle opening device - Re-
placement
4 002083 Saddle opening transmission - Re-
placement
5 005072 Immobilizer aerial - Replacement

TIME - 315
Time Beverly 300 i.e.

Turn signal lights

INDICATOR LIGHTS
Code Action Duration
1 005002 Front light - replacement
2 005008 Headlight bulbs - Replacement

TIME - 316
Beverly 300 i.e. Time

Code Action Duration

3 005067 Front turning indicator bulb - replace-
ment
4 005012 Front turning indicators - Replace-
ment
5 005066 Rear light bulbs - Replacement
6 005005 Taillight - change
7 005032 number plate light glass - Replace-
ment
8 005031 number plate light bulb - Replace-
ment
9 005068 Rear turning indicator bulb - Re-
placement

Front wheel

FRONT WHEEL
Code Action Duration
1 003038 Front wheel axle - Replacement
2 002011 Odometer drive - Replacement
3 003040 Front wheel bearings - Replacement
4 003047 Front tyre - Replacement
5 003037 Front wheel rim - Replacement
6 002041 Front brake disc - Replacement
7 004123 Front wheel - Replacement

TIME - 317
Time Beverly 300 i.e.

Rear wheel

REAR WHEEL
Code Action Duration
1 001016 Rear wheel - Replacement
2 004126 Rear wheel tyre - Replacement
3 001071 Rear wheel rim - Replacement
4 002070 Rear brake disc - Replacement

TIME - 318
Beverly 300 i.e. Time

Fuel pump

FUEL PUMP
Code Action Duration
1 004073 Fuel pump - Replacement
2 004137 Injector pump pipe - Replacement

TIME - 319
Time Beverly 300 i.e.

Electric devices

VOLTAGE REGULATOR
Code Action Duration
1 005009 Voltage regulator - Replacement
2 001069 HV coil - Replacement
3 001094 Spark plug cap - Replacement

TIME - 320
Beverly 300 i.e. Time

CONTACTORS
Code Action Duration
1 005035 Headlight solenoid - Replacement
2 005096 Injection Component contactor - Re-
placement
3 005117 Electric fan contactor - Replacement
4 005003 Horn - Replacement
5 005011 Starter relay - Replacement
6 005007 Battery - change

TIME - 321
Time Beverly 300 i.e.

WIRE UNIT
Code Action Duration
1 005054 Fuse holder - Replacement
2 005052 Fuse - Replacement
3 005001 Electrical system - Replacement

TIME - 322
Beverly 300 i.e. Time

Electronic controls

ELECTRIC CONTROLS
Code Action Duration
1 005039 Lights switch - Replacement
2 005006 Light or turning indicator switch - Re-
placement
3 005040 Horn button - Replacement
4 005121 Saddle opening button - Replace-
ment
5 005041 Starter button - Replacement
6 005077 Emergency stop switch - Replace-
ment
7 005017 Stop switch - Replacement

TIME - 323
Time Beverly 300 i.e.

Transmissions

TRANSMISSIONS
Code Action Duration
1 002051 Odometer transmission assembly -
Replacement
2 002049 Odometer cable - Replacement
3 002082 Fuel tank door opening drive - Re-
placement

TIME - 324
Beverly 300 i.e. Time

Front suspension

FRONT SUSPENSION
Code Action Duration
1 003051 Complete fork - Replacement
2 003010 Front suspension - Service
3 003076 Fork sheath - Replacement
4 003079 Fork stem - Replacement
5 003048 Fork oil seal - Replacement
6 003002 Steering fifth wheels - Replacement
7 003073 Steering clearance - Adjustment

TIME - 325
Time Beverly 300 i.e.

Cooling system

RADIATOR
Code Action Duration
1 007001 Expansion tank - Replacement
2 007024 Expansion tank cap - Replacement
3 007013 Radiator expansion tank connection
pipe - change
4 007016 Fan with support - Replacement
5 001052 Coolant and air bleed - Replacement
6 007003 Coolant delivery and return pipe -
change

TIME - 326
Beverly 300 i.e. Time

Windscreen

WINDSCREEN
Code Action Duration
1 004028 Windshield glass - Replacement

TIME - 327
Time Beverly 300 i.e.

Stickers

TRANSFERS
Code Action Duration
1 004159 Plates / Stickers - Replacement

TIME - 328
A
Air filter: 42

B
Battery: 71, 81, 92, 93, 269
Brake: 233–235, 237–240, 242, 243, 311
Brake fluid: 242
Bulbs:

C
Checks: 75
Coolant: 196

E
Electric: 247, 320
Engine oil: 43

F
Fuel: 176, 184, 306, 319
Fuses: 90

H
Headlight: 50, 255
Horn: 87
Hub oil: 41

I
Identification: 8
Instrument panel: 59, 255, 313

L
Luggage rack:

M
Maintenance: 7, 40

O
Oil filter: 45, 284

R
Recommended products:

S
Saddle:
Shock absorbers: 226
Spark plug: 41, 80
Stand: 231
Start-up: 274
Suspension: 54, 325

T
Tank: 269, 306
Transmission: 9, 53, 109, 123, 290
Turn indicators: 74
Tyres: 10

V
Vehicle: 8, 102, 103