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PIAGGIO
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Beverly 300 i.e.
PIAGGIO Beverly 300 i.e. User Manual
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Front suspension
FRONT SUSPENSION
Code
Action
Duration
1
003051
Complete fork - Replacement
2
003010
Front suspension - Service
3
003076
Fork sleeve - Replacement
4
003079
Fork stem - Replacement
5
003048
Fork oil seal - Replacement
6
003002
Steering fifth wheels - Replacement
7
003073
Steering clearance - Adjustment
Beverly 300 i.e.
Time
TIME - 333
332
334
Table of Contents
Index of Topics
5
Characteristics
6
Safety Rules
7
Maintenance Rules
7
Vehicle Identification
8
Dimensions and Mass
8
Chassis Number
8
Engine Number
8
Weights and Dimensions
9
Engine Data
9
Transmission Data
9
Capacities
9
Electrical System Data
10
Frame and Suspensions Data
10
Brakes Data
10
Wheels and Tyres Data
10
Front Brake Data
11
Rear Brake Data
11
Muffler Data
11
Lubrication Data
11
Overhaul Data
12
Assembly Clearances
12
Flywheel Data
12
Crankcase and Crankshaft Data
12
Cylinder - Piston Assy Assembly Clearances
13
Crankcase - Crankshaft - Connecting Rod Assembly Clearances
15
Crankshaft View
16
Max Admissible Displacement
17
Crankshaft-Crankcase Axial Clearance (H)
18
Bushings
18
Couplings
19
Crankshaft Category Identification
19
Cylinder Head
20
Slot Packing System
26
Engine 300 Shimming
27
Recommended Products Table
27
Units of Measure Conversion
27
Tooling
28
Specific Tools
29
Maintenance
39
Reset Service Warning Light
40
Maintenance Chart
40
Spark Plug
41
Hub Oil Check
41
Hub Oil Replacement
42
Air Filter
42
Engine Oil Replacement
43
Engine Oil Check
45
Engine Oil Filter
45
Oil Pressure Warning Light
46
Cooling System: Level Check
46
Braking System: Level Check
47
Top-Up
48
Headlight Adjustment
50
Troubleshooting
51
Engine Poor Performance
52
Starting Difficulties
52
Excessive Oil Consumption/Exhaust Smoke
52
Insufficient Lubrication Pressure
53
Clutch Grabbing or Performing Inadequately
53
Insufficient Braking
53
Brakes Overheating
53
Heavy Steering
54
Excessive Steering Play
54
Noisy Suspension
54
Suspension Oil Leakage
54
Electrical System
55
Electrical Components Arrangement
56
Instrument Panel
59
Ground Points
60
Electrical System Installation
60
Electrical Components View: Front Side
61
Electrical Components View: Back Side
64
Conceptual Diagrams
67
Ignition Diagram
70
Battery Recharge and Starting Diagram
71
Level Indicators and Enable Signals Section Diagram
72
Devices and Accessories Diagram
73
Lights and Turn Indicators Diagram
74
Checks and Inspections of the Electrical Components
75
Immobiliser Check
75
Virgin Circuit Check
78
Diagnostic Codes of the Immobilizer Sistem
78
Diagnostic Code - 1 Flash
79
Diagnostic Code - 2 Flashes
80
Diagnostic Code - 3 Flashes
80
Ignition Circuit
80
No Spark Plug
80
HV Coil Secondary Resistance Value
81
Battery Recharge Circuit
81
Remote Controls Check
81
Switches Check
82
Engine Stop Switch Check
82
Starter Button Check
82
Light Switch Check
82
Turn Indicator Switch
83
Horn Button
83
Helmet Compartment Light Switch
83
Saddle Opening Switch
83
Stator Check
84
Mode Button Check
84
Stand Button Check
84
Stop Buttons Check
84
Voltage Regulator Check
85
Recharge System Voltage Check
85
Starter Motor Schematic Diagram
86
Horn Control
87
Turn Signals System Check
88
Level Indicators
89
Lights List
89
Fuses
90
Dashboard
92
Sealed Battery
92
Battery Installation
93
Battery Preparation
93
Electrolyte Preparation
94
Procedure for Filling the Battery with Acid
94
Control the Flow of Electrolyte
94
Battery Closing
94
Recharging the New Battery
95
Connectors
97
Instrument Panel Connector a
97
Instrument Panel Connector B
97
Fuel Pump Connector
97
Electric Fan Connector
98
Pickup Connector
98
Antitheft Device Pre-Installation
98
Voltage Regulator Connector
98
Injection Electronic Control Unit Connector
99
Injector Connector
99
HV Coil Connector
100
Fuel Level Transmitter Connector
100
Coolant Temperature Sensor Connector
100
Engine from Vehicle
101
Exhaust Assy. Removal
102
Removal of the Engine from the Vehicle
103
Engine
108
Automatic Transmission
109
Transmission Cover
109
Air Duct
109
Removing the Driven Pulley Shaft Bearing
110
Refitting the Driven Pulley Shaft Bearing
110
Removing the Driven Pulley
111
Inspecting the Clutch Drum
111
Removing the Clutch
112
Inspecting the Clutch
113
Pin Retaining Collar
113
Removing the Driven Half-Pulley Bearing
114
Inspecting the Driven Fixed Half-Pulley
114
Inspecting the Driven Sliding Half-Pulley
115
Refitting the Driven Half-Pulley Bearing
116
Refitting the Driven Pulley
116
Inspecting the Clutch Spring
117
Refitting the Clutch
117
To Refit the Driven Pulley
119
Drive-Belt
119
Removing the Driving Pulley
119
Inspecting the Rollers Case
121
Refitting the Driving Pulley
122
Refitting the Transmission Cover
123
End Gear
123
Removing the Hub Cover
124
Removing the Wheel Axle
124
Removing the Hub Bearings
125
Removing the Wheel Axle Bearings
125
To Remove the Driven Pulley Shaft Bearing
126
Inspecting the Hub Shaft
126
Inspecting the Hub Cover
127
Refitting the Wheel Axle Bearing
128
Refitting the Hub Cover Bearings
129
Refitting the Hub Bearings
130
Refitting the Hub Cover
130
Flywheel Cover
130
To Remove the Hub Cover
131
Removing the Stator
132
Refitting the Stator
132
Refitting the Flywheel Cover
132
Flywheel and Starting
133
Removing the Starter Motor
134
Removing the Flywheel Magneto
134
Inspecting the Flywheel Components
135
Starter Gear Rim
135
Intermediate Gear
136
Refitting the Free Wheel
136
Refitting the Flywheel Magneto
137
Refitting the Starter Motor
137
Cylinder Assy. and Timing System
138
Removing the Intake Manifold
138
Removing the Rocker-Arms Cover
138
Removing the Timing System Drive
138
Removing the Cam Shaft
139
Removing the Cylinder Head
140
Removing the Valves
141
Removing the Cylinder - Piston Assy.
142
Inspecting the Small End
142
Inspecting the Wrist Pin
142
Inspecting the Piston
143
Inspecting the Piston Rings
143
Removing the Piston
143
Choosing the Gasket
144
Refitting the Piston Rings
145
Refitting the Cylinder
145
Inspecting the Cylinder Head
146
Inspecting the Timing System Components
146
Inspecting the Valve Sealings
147
Inspecting the Valves
147
Inspecting the Springs and Half-Cones
147
Refitting the Valves
148
Inspecting the Cam Shaft
148
Refitting the Head and Timing System Components
148
Refitting the Rocker-Arms Cover
151
Refitting the Intake Manifold
151
Crankcase - Crankshaft
151
Splitting the Crankcase Halves
151
Inspecting the Crankshaft Components
153
Inspecting the Crankshaft Alignment
153
Inspecting the Crankcase Halves
154
Inspecting the Crankshaft Plain Bearings
155
Coupling Chart
155
Refitting the Crankcase Halves
156
Studs
157
Lubrication Conceptual Diagrams
158
Oil Pressure Check
159
Crankshaft Oil Seals
159
Crankshaft Oil Seals Removal
160
Crankshaft Oil Seals Refitting
160
Oil Pump
161
Oil Pump Removal
162
Oil Pump Inspection
162
Oil Pump Refitting
163
Removing the Oil Sump
164
Inspecting the By-Pass Valve
165
Refitting the Oil Sump
165
Injection
166
MIU Injection System
167
Precautions (MIU)
169
Terminals Setup
171
EMS Circuit Diagram
172
Injection: Troubleshooting Procedure
173
Engine Does Not Start
173
System Diagram
173
Engine Stops at Idle
174
Engine Does Not Rev down
174
Exhaust Backfires in Deceleration
175
Engine Revs Irregularly
175
Poor Performance at Full Throttle
176
Engine Knocking
176
Fuel Supply System
176
Removing the Butterfly Valve
177
Refitting the Butterfly Valve
179
Pump Supply Circuit
180
Circuit Leak Test
183
Fuel Filter Check
184
Inspecting the Injector Circuit
185
Inspecting the Injector Hydraulics
189
Components Location
190
Tachometer
191
HT Coil
192
Coolant Temperature Sensor
196
Zeroing the Throttle
197
Lambda Probe
199
Suspensions
201
Front Suspension
202
Removing the Front Wheel
202
Front Wheel Hub Overhaul
202
Refitting the Front Wheel
205
Handlebar Removal
205
Handlebar Refitting
206
Front Fork Removal and Ovehaul
206
Front Fork Refitting
210
Steering Column Removal
213
Steering Column Refitting
214
Steering Bearing Removal
217
Steeringh Fifth Wheel Track Removal
218
Steeringh Fifth Wheel Track Refitting
219
Rear Suspension
220
Removing the Rear Wheel
220
Refitting the Rear Wheel
220
Swingarm
220
Swingarm Removal
221
Swingarm Overhaul
221
Swinging Arm Service
224
Swinging Arm Refitting
225
Swinging Arm Fittings
226
Shock Absorbers
226
Shock Absorbers Removal
227
Shock Absorbers Refitting
227
Exhaust Bracket Removal
227
Exhaust Bracket Overhaul
230
Exhaust Bracket Refitting
230
Centre-Stand
231
Side Stand
231
Braking System
232
Braking System: Interventions Rules
233
Rear Brake Caliper
233
Rear Brake Caliper Removal
234
Rear Brake Caliper Refitting
234
Front Brake Caliper
234
Front Brake Caliper Removal
235
Front Brake Caliper Refitting
235
Rear Brake Disc Removal
235
Rear Brake Disc Refitting
236
Disc Inspection
237
Front Brake Disc Removal
237
Front Brake Disc Refitting
237
Front Brake Pads
238
Front Brake Pads Removal
239
Front Brake Pads Refitting
239
Rear Brake Pads Removal
240
Rear Brake Pads Refitting
241
Fill - Rear Combined
241
Fill - Front
242
Brake Fluid Level Check
242
Front Brake Pump Removal
243
Front Brake Pump Refitting
243
Rear Brake Pump - Combined
243
Rear Brake Pump - Combined, Removal
244
Rear Brake Pump - Combined, Refitting
244
Cooling System
245
Cooling System Circuit Diagram
246
Cooling System Specifications
247
Electric Fan Check
247
Cooling System Bleed
248
Thermostat Removal
249
Thermostat Check
250
Thermostat Refitting
250
Chassis
251
Seat
252
Rear Rack
252
Rear Handlebar Cover
253
Front Handlebar Cover
255
Headlight Assy.
255
Frame Central Cover
255
Legshield
256
Knee-Guard
258
Removing the Ignition Key-Switch When on off
260
Removing the Ignition Key-Switch When on *Lock*
261
Front Wheel Housing
261
Taillight Assy.
262
Footrest
262
Side Fairings
263
License Plate Holder
265
Helmet Bay
265
Fuel Tank Diagram
267
Fuel Tank Removal
268
Front Mudguard
276
Radiator Fan
277
Expansion Tank
277
Battery
278
Pre-Delivery
279
Aesthetic Inspection
280
Tightening Torques Inspection
280
Electrical System Inspection
280
Levels Check
281
Road Test
281
Test Ride
281
Static Test
282
Functional Inspection
282
Instruments Start-Up
282
Trip Counter Partial Reset
283
Select Miles - Km
283
Time
284
Engine Diagram
285
Crankcase Diagram
286
Crankshaft Diagram
287
Cylinder Assy Diagram
288
Cylinder Head Assy Diagram
289
Rocker Arms Support Assy Diagram
290
Cylinder Head Cover Diagram
291
Oil Filter Diagram
292
Flywheel Cover Diagram
293
Driven Pulley Diagram
294
Oil Pump Diagram
295
Final Gear Assy Diagram
296
Final Reduction
296
Driving Pulley Diagram
297
Transmission Cover Diagram
298
Water Pump Diagram
299
Starter Motor Diagram
300
Flywheel Magneto Diagram
301
Butterfly Valve Diagram
302
Exhaust Pipe Diagram
303
Air Cleaner Diagram
304
Frame Diagram
305
Centre-Stand Diagram
306
Legshield Spoiler Diagram
307
Side Fairings Diagram
308
Rear Cover Diagram
309
Central Cover Diagram
310
Underseat Compartment
311
Plate Holder Diagram
312
Mudguard Diagram
313
Fuel Tank Exploded View
314
Rear Shock-Absorber Diagram
315
Handlebar Covers Diagram
316
Handlebar Components Diagram
317
Swing-Arm Diagram
318
Brake Hoses Diagram
319
Seat Diagram
320
Instrument Panel Diagram
321
Rear Rack Diagram
322
Locks Diagram
323
Turn Signal Lights Diagram
324
Front Wheel Diagram
325
Rear Wheel Diagram
326
Fuel Pump Diagram
327
Electric Devices Diagrams
328
Voltage Regulator Diagram
328
Remote Controls Diagram
329
Cable Assembly Diagram
330
Electronic Controls Diagram
331
Transmissions Diagram
332
Front Suspension Diagram
333
Cooling System Diagram
334
Windscreen Diagram
335
Stickers Diagram
336
Index
337
4
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PIAGGIO Beverly 300 i.e. Specifications
General
Brand
PIAGGIO
Model
Beverly 300 i.e.
Category
Scooter
Language
English
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