PIAGGIO Beverly 300 i.e.

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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

020922Y Diagnosis Tool

020621Y HV cable extraction adaptor

Beverly 300 i.e. Tooling

TOOL - 35

Main Page

Index of Topics5
Characteristics6
Safety Rules7
Maintenance Rules7
Vehicle Identification8
Dimensions and Mass8
Chassis Number8
Engine Number8
Weights and Dimensions9
Engine Data9
Transmission Data9
Capacities9
Electrical System Data10
Frame and Suspensions Data10
Brakes Data10
Wheels and Tyres Data10
Front Brake Data11
Rear Brake Data11
Muffler Data11
Lubrication Data11
Overhaul Data12
Assembly Clearances12
Flywheel Data12
Crankcase and Crankshaft Data12
Cylinder - Piston Assy Assembly Clearances13
Crankcase - Crankshaft - Connecting Rod Assembly Clearances15
Crankshaft View16
Max Admissible Displacement17
Crankshaft-Crankcase Axial Clearance (H)18
Bushings18
Couplings19
Crankshaft Category Identification19
Cylinder Head20
Slot Packing System26
Engine 300 Shimming27
Recommended Products Table27
Units of Measure Conversion27
Tooling28
Specific Tools29
Maintenance39
Reset Service Warning Light40
Maintenance Chart40
Spark Plug41
Hub Oil Check41
Hub Oil Replacement42
Air Filter42
Engine Oil Replacement43
Engine Oil Check45
Engine Oil Filter45
Oil Pressure Warning Light46
Cooling System: Level Check46
Braking System: Level Check47
Top-Up48
Headlight Adjustment50
Troubleshooting51
Engine Poor Performance52
Starting Difficulties52
Excessive Oil Consumption/Exhaust Smoke52
Insufficient Lubrication Pressure53
Clutch Grabbing or Performing Inadequately53
Insufficient Braking53
Brakes Overheating53
Heavy Steering54
Excessive Steering Play54
Noisy Suspension54
Suspension Oil Leakage54
Electrical System55
Electrical Components Arrangement56
Instrument Panel59
Ground Points60
Electrical System Installation60
Electrical Components View: Front Side61
Electrical Components View: Back Side64
Conceptual Diagrams67
Ignition Diagram70
Battery Recharge and Starting Diagram71
Level Indicators and Enable Signals Section Diagram72
Devices and Accessories Diagram73
Lights and Turn Indicators Diagram74
Checks and Inspections of the Electrical Components75
Immobiliser Check75
Virgin Circuit Check78
Diagnostic Codes of the Immobilizer Sistem78
Diagnostic Code - 1 Flash79
Diagnostic Code - 2 Flashes80
Diagnostic Code - 3 Flashes80
Ignition Circuit80
No Spark Plug80
HV Coil Secondary Resistance Value81
Battery Recharge Circuit81
Remote Controls Check81
Switches Check82
Engine Stop Switch Check82
Starter Button Check82
Light Switch Check82
Turn Indicator Switch83
Horn Button83
Helmet Compartment Light Switch83
Saddle Opening Switch83
Stator Check84
Mode Button Check84
Stand Button Check84
Stop Buttons Check84
Voltage Regulator Check85
Recharge System Voltage Check85
Starter Motor Schematic Diagram86
Horn Control87
Turn Signals System Check88
Level Indicators89
Lights List89
Fuses90
Dashboard92
Sealed Battery92
Battery Installation93
Battery Preparation93
Electrolyte Preparation94
Procedure for Filling the Battery with Acid94
Control the Flow of Electrolyte94
Battery Closing94
Recharging the New Battery95
Connectors97
Instrument Panel Connector a97
Instrument Panel Connector B97
Fuel Pump Connector97
Electric Fan Connector98
Pickup Connector98
Antitheft Device Pre-Installation98
Voltage Regulator Connector98
Injection Electronic Control Unit Connector99
Injector Connector99
HV Coil Connector100
Fuel Level Transmitter Connector100
Coolant Temperature Sensor Connector100
Engine from Vehicle101
Exhaust Assy. Removal102
Removal of the Engine from the Vehicle103
Engine108
Automatic Transmission109
Transmission Cover109
Air Duct109
Removing the Driven Pulley Shaft Bearing110
Refitting the Driven Pulley Shaft Bearing110
Removing the Driven Pulley111
Inspecting the Clutch Drum111
Removing the Clutch112
Inspecting the Clutch113
Pin Retaining Collar113
Removing the Driven Half-Pulley Bearing114
Inspecting the Driven Fixed Half-Pulley114
Inspecting the Driven Sliding Half-Pulley115
Refitting the Driven Half-Pulley Bearing116
Refitting the Driven Pulley116
Inspecting the Clutch Spring117
Refitting the Clutch117
To Refit the Driven Pulley119
Drive-Belt119
Removing the Driving Pulley119
Inspecting the Rollers Case121
Refitting the Driving Pulley122
Refitting the Transmission Cover123
End Gear123
Removing the Hub Cover124
Removing the Wheel Axle124
Removing the Hub Bearings125
Removing the Wheel Axle Bearings125
To Remove the Driven Pulley Shaft Bearing126
Inspecting the Hub Shaft126
Inspecting the Hub Cover127
Refitting the Wheel Axle Bearing128
Refitting the Hub Cover Bearings129
Refitting the Hub Bearings130
Refitting the Hub Cover130
Flywheel Cover130
To Remove the Hub Cover131
Removing the Stator132
Refitting the Stator132
Refitting the Flywheel Cover132
Flywheel and Starting133
Removing the Starter Motor134
Removing the Flywheel Magneto134
Inspecting the Flywheel Components135
Starter Gear Rim135
Intermediate Gear136
Refitting the Free Wheel136
Refitting the Flywheel Magneto137
Refitting the Starter Motor137
Cylinder Assy. and Timing System138
Removing the Intake Manifold138
Removing the Rocker-Arms Cover138
Removing the Timing System Drive138
Removing the Cam Shaft139
Removing the Cylinder Head140
Removing the Valves141
Removing the Cylinder - Piston Assy.142
Inspecting the Small End142
Inspecting the Wrist Pin142
Inspecting the Piston143
Inspecting the Piston Rings143
Removing the Piston143
Choosing the Gasket144
Refitting the Piston Rings145
Refitting the Cylinder145
Inspecting the Cylinder Head146
Inspecting the Timing System Components146
Inspecting the Valve Sealings147
Inspecting the Valves147
Inspecting the Springs and Half-Cones147
Refitting the Valves148
Inspecting the Cam Shaft148
Refitting the Head and Timing System Components148
Refitting the Rocker-Arms Cover151
Refitting the Intake Manifold151
Crankcase - Crankshaft151
Splitting the Crankcase Halves151
Inspecting the Crankshaft Components153
Inspecting the Crankshaft Alignment153
Inspecting the Crankcase Halves154
Inspecting the Crankshaft Plain Bearings155
Coupling Chart155
Refitting the Crankcase Halves156
Studs157
Lubrication Conceptual Diagrams158
Oil Pressure Check159
Crankshaft Oil Seals159
Crankshaft Oil Seals Removal160
Crankshaft Oil Seals Refitting160
Oil Pump161
Oil Pump Removal162
Oil Pump Inspection162
Oil Pump Refitting163
Removing the Oil Sump164
Inspecting the By-Pass Valve165
Refitting the Oil Sump165
Injection166
MIU Injection System167
Precautions (MIU)169
Terminals Setup171
EMS Circuit Diagram172
Injection: Troubleshooting Procedure173
Engine Does Not Start173
System Diagram173
Engine Stops at Idle174
Engine Does Not Rev down174
Exhaust Backfires in Deceleration175
Engine Revs Irregularly175
Poor Performance at Full Throttle176
Engine Knocking176
Fuel Supply System176
Removing the Butterfly Valve177
Refitting the Butterfly Valve179
Pump Supply Circuit180
Circuit Leak Test183
Fuel Filter Check184
Inspecting the Injector Circuit185
Inspecting the Injector Hydraulics189
Components Location190
Tachometer191
HT Coil192
Coolant Temperature Sensor196
Zeroing the Throttle197
Lambda Probe199
Suspensions201
Front Suspension202
Removing the Front Wheel202
Front Wheel Hub Overhaul202
Refitting the Front Wheel205
Handlebar Removal205
Handlebar Refitting206
Front Fork Removal and Ovehaul206
Front Fork Refitting210
Steering Column Removal213
Steering Column Refitting214
Steering Bearing Removal217
Steeringh Fifth Wheel Track Removal218
Steeringh Fifth Wheel Track Refitting219
Rear Suspension220
Removing the Rear Wheel220
Refitting the Rear Wheel220
Swingarm220
Swingarm Removal221
Swingarm Overhaul221
Swinging Arm Service224
Swinging Arm Refitting225
Swinging Arm Fittings226
Shock Absorbers226
Shock Absorbers Removal227
Shock Absorbers Refitting227
Exhaust Bracket Removal227
Exhaust Bracket Overhaul230
Exhaust Bracket Refitting230
Centre-Stand231
Side Stand231
Braking System232
Braking System: Interventions Rules233
Rear Brake Caliper233
Rear Brake Caliper Removal234
Rear Brake Caliper Refitting234
Front Brake Caliper234
Front Brake Caliper Removal235
Front Brake Caliper Refitting235
Rear Brake Disc Removal235
Rear Brake Disc Refitting236
Disc Inspection237
Front Brake Disc Removal237
Front Brake Disc Refitting237
Front Brake Pads238
Front Brake Pads Removal239
Front Brake Pads Refitting239
Rear Brake Pads Removal240
Rear Brake Pads Refitting241
Fill - Rear Combined241
Fill - Front242
Brake Fluid Level Check242
Front Brake Pump Removal243
Front Brake Pump Refitting243
Rear Brake Pump - Combined243
Rear Brake Pump - Combined, Removal244
Rear Brake Pump - Combined, Refitting244
Cooling System245
Cooling System Circuit Diagram246
Cooling System Specifications247
Electric Fan Check247
Cooling System Bleed248
Thermostat Removal249
Thermostat Check250
Thermostat Refitting250
Chassis251
Seat252
Rear Rack252
Rear Handlebar Cover253
Front Handlebar Cover255
Headlight Assy.255
Frame Central Cover255
Legshield256
Knee-Guard258
Removing the Ignition Key-Switch When on off260
Removing the Ignition Key-Switch When on *Lock*261
Front Wheel Housing261
Taillight Assy.262
Footrest262
Side Fairings263
License Plate Holder265
Helmet Bay265
Fuel Tank Diagram267
Fuel Tank Removal268
Front Mudguard276
Radiator Fan277
Expansion Tank277
Battery278
Pre-Delivery279
Aesthetic Inspection280
Tightening Torques Inspection280
Electrical System Inspection280
Levels Check281
Road Test281
Test Ride281
Static Test282
Functional Inspection282
Instruments Start-Up282
Trip Counter Partial Reset283
Select Miles - Km283
Time284
Engine Diagram285
Crankcase Diagram286
Crankshaft Diagram287
Cylinder Assy Diagram288
Cylinder Head Assy Diagram289
Rocker Arms Support Assy Diagram290
Cylinder Head Cover Diagram291
Oil Filter Diagram292
Flywheel Cover Diagram293
Driven Pulley Diagram294
Oil Pump Diagram295
Final Gear Assy Diagram296
Final Reduction296
Driving Pulley Diagram297
Transmission Cover Diagram298
Water Pump Diagram299
Starter Motor Diagram300
Flywheel Magneto Diagram301
Butterfly Valve Diagram302
Exhaust Pipe Diagram303
Air Cleaner Diagram304
Frame Diagram305
Centre-Stand Diagram306
Legshield Spoiler Diagram307
Side Fairings Diagram308
Rear Cover Diagram309
Central Cover Diagram310
Underseat Compartment311
Plate Holder Diagram312
Mudguard Diagram313
Fuel Tank Exploded View314
Rear Shock-Absorber Diagram315
Handlebar Covers Diagram316
Handlebar Components Diagram317
Swing-Arm Diagram318
Brake Hoses Diagram319
Seat Diagram320
Instrument Panel Diagram321
Rear Rack Diagram322
Locks Diagram323
Turn Signal Lights Diagram324
Front Wheel Diagram325
Rear Wheel Diagram326
Fuel Pump Diagram327
Electric Devices Diagrams328
Voltage Regulator Diagram328
Remote Controls Diagram329
Cable Assembly Diagram330
Electronic Controls Diagram331
Transmissions Diagram332
Front Suspension Diagram333
Cooling System Diagram334
Windscreen Diagram335
Stickers Diagram336
Index337

PIAGGIO Beverly 300 i.e. - Page 35

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