Beverly 400 E5

MANUALE STAZIONE DI SERVIZIO
1Q000884
Beverly 400 E5
MANUALE
STAZIONE DI
SERVIZIO
Beverly 400 E5
The descriptions and images in this publication are given for illustrative purposes only. While the basic
features as described and illustrated in this manual remain unchanged, Piaggio & C. S.p.A. reserves the
right, at any time and without being required to update this publication beforehand, to make any changes
to components, parts or accessory supplies which it deems necessary to improve the product, or which
are required for manufacturing or commercial reasons.
Not all the versions shown in this publication are available in every country. Availability of the individual
versions must be verified with the official PIAGGIO sales network.
© Copyright 2021 - Piaggio & C. S.p.A. All rights reserved. Reproduction of this publication in whole or
in part is prohibited.
Piaggio & C. S.p.A. Viale Rinaldo Piaggio, 25 - 56025 PONTEDERA (PI), Italy
www.piaggio.com
MANUALE STAZIONE DI
SERVIZIO
Beverly 400 E5
Questo manuale per stazioni di servizio è stato realizzato da Piaggio & C. Spa per essere utilizzato dalle
officine dei concessionari e sub-agenzie Piaggio. 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
GENERAL MANDATORY REQUIREMENTS

NORM
PRE-DELIVERY PRE DE
TECHNICAL DATA DT
TOOLING TOOL
MAINTENANCE MAIN
ELECTRICAL SYSTEM ELE SYS
ENGINE ENG
BRAKING SYSTEM BRAK SYS

INDEX OF TOPICS
GENERAL MANDATORY REQUIREMENTS NORM

Beverly 400 E5 General mandatory requirements
General information
This section contains general information about using the manual and the vehicle. as well as important
notes about safety.
WARNINGS AND IMPORTANT NOTES

Each symbol has a precise meaning. as shown below.
• WARNING: - This symbol indicates the risk to the health of the operator or others in the
vicinity if the procedures are not carried out properly.
• IMPORTANT!:- This symbol indicates that the component being worked on may be dam-
aged if the described procedures are not carried out properly.
• N.B.:- This section provides additional instructions on the procedure in progress so that the
operation may be performed effectively.
WARNINGS REACH REGULATION:

In order to preserve the health and safety of the PROFESSIONAL CUSTOMER, as required by:
• EC Regulation 1907/2006 (REACH);

• EC Directive 2000/53/EC (END of LIFE VEHICLES);
• SCIP Database Directive (Article 9, paragraph 1 letter i) of the Waste Framework Directive,
amended by Directive 2018/851
All technical personnel working engaged in scheduled and unscheduled maintenance activities are
required to wear the following personal protective equipment at all times:
1. chemical resistant gloves, where a specific type is not indicated, or, where required, specific
gloves for the substance handled;
2. face mask or, where specifically indicated, chemical filter mask;
3. protective eyewear.
The above is valid in the alternative to what is required by other regulations and by the laws in force in
specific countries. As regarding the use of other PPE, regulated by safety at work, the regulations in
force apply.
NORM - 7
General mandatory requirements Beverly 400 E5
GENERAL SAFETY WARNINGS:
1. Always wear protective goggles and suitable clothing.

2. Always use a safety support for operating under the vehicle.
3. Make sure the ignition switch is always OFF. unless otherwise specified in the procedure.
4. Pull the hand brake (if available) before starting work on the vehicle.
5. Operate the engine only in well ventilated places to avoid the risks associated with carbon mon-
oxide.
6. Keep away from moving parts during engine operation. especially from the fans and belts.
7. To avoid serious burns. avoid contact with hot metal parts such as the radiator. exhaust manifold.
exhaust pipe. catalytic converter and muffler.
8. Do not smoke during maintenance operations.
9. To avoid possible injury. do not wear rings. watches. jewellery or loose clothing before beginning
work on the vehicle.
10.Keep hands and other objects away from the radiator electric fan blades (if available)!
11.The electric cooling fan (if available) is mounted on the radiator and can start up at any time due
to an increase in coolant temperature. It is important to verify that the electric cooling fan motor
has been disconnected from the cable harness before starting work.
The units of measurement used in this manual are indicated as SI UNITS (International System
of Units). Example:24.5 to 34.3 Nm
NORM - 8
INDEX OF TOPICS
PRE-DELIVERY PRE DE
Pre-delivery Beverly 400 E5
Electrical system
• Remote control and ignition switch

• Lights: high beam lights, low beam lights, tail lights and their warning lights
- Headlight adjustment according to the regulations currently in force
• Brake light operation by using the RH and LF brake lever
• Turn indicators and their warning lights
• Instrument lighting
• instruments: fuel and temperature indicator
•Instrument panel lights
• Horn
• Electric starter
• Engine stopping with emergency stop switch
• Various controls on the handlebar
TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE.
INADEQUATELY CHARGING THE BATTERY WITH A LOW ELECTROLYTE LEVEL BEFORE IT IS
USED FOR THE FIRST TIME WITH SHORTEN 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 EYES, SKIN AND CLOTHING.
IF IT ACCIDENTALLY COMES INTO CONTACT WITH YOUR EYES OR SKIN, WASH WITH ABUN-
DANT WATER FOR APPROX. 15 MIN. AND SEEK IMMEDIATE MEDICAL ATTENTION.
IF ACCIDENTALLY SWALLOWED, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR
VEGETABLE OIL. SEEK IMMEDIATE MEDICAL ATTENTION.
BATTERIES PRODUCE EXPLOSIVE GAS; KEEP CLEAR OF NAKED FLAMES, SPARKS OR CIG-
ARETTES. VENTILATE THE AREA WHEN RECHARGING INDOORS. ALWAYS WEAR EYE PRO-
TECTION WHEN WORKING IN THE PROXIMITY OF 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.
The vehicle is equipped with an OBD (On-Board
Diagnostics) port, compliant with the Euro 5 direc-
tives and which allows the connection between the
vehicle and the diagnostic tool.
N.B.
AT EACH SCHEDULED MAINTENANCE A VERIFICATION
MUST BE PERFORMED WITH THE DIAGNOSTIC TOOL TO
CHECK IF THERE ARE ERRORS AND THE IF THE PARAM-
ETERS ARE CORRECT. ENSURE THAT THE VEHICLE
CALIBRATION IS UP TO DATE AFTER UPDATING THE DI-
AGNOSTIC TOOL.
PRE DE - 10
Beverly 400 E5 Pre-delivery
Instruments start-up
DIGITAL DISPLAY MEASUREMENT UNIT CON-

VERSION (Km-mi, l-gal, °C-°F)
• With the ignition switch turned to

"OFF", press and hold the MODE key
on the instrument cluster and simulta-
neously turn the ignition switch to
"ON";
• release the button. The icons "mi",
"km", "°C", "°F" will flash;
• briefly press the MODE button, until the
desired icon is displayed (steady);
• press and hold the MODE for at least 1
to 5 seconds to change the unit of
measurement;
• the consumption measurement unit
will automatically change when "Km"
or "mi" is selected.
N.B.
THE MEASUREMENT UNIT CONVERSION CAN TAKE
PLACE ONLY WITH THE VEHICLE AT A STANDSTILL.
CLOCK SETTING
To set or adjust the time, with the engine running

or with the ignition switch to "ON" position, proceed
as follows:
• press and hold the SET button on the

instrument cluster for at least 5 sec-
onds and then release the button; the
hour value "hh" starts flashing;
• press the SET button briefly and re-
peatedly to set the correct hour value;
press and hold the SET button to cycle
the hour value rapidly;
• press the SET twice in succession
briefly to confirm the set value (or cur-
PRE DE - 11
rent value, if no changes were made) -

the minutes value «mm» now starts
flashing;
peatedly to set the correct minutes val-
ue; press and hold the SET button to
cycle the minutes value rapidly;
rent value, if no changes were made).
If the SET button is not pressed for a period ex-

ceeding 5 seconds at any time during this proce-
dure, the system exits clock setting mode.
WARNING
FOR SAFETY REASONS THE TIME SETTING IS ONLY

POSSIBLE WITH THE VEHICLE AT A STANDSTILL.
WARNING
DISCONNECTING THE BATTERY CABLES WILL RESULT

IN A RESET OF THE CLOCK
ASR SYSTEM
The ASR system is a driving aid that assists the

driver in acceleration manoeuvres, particularly on
low-grip surfaces or under conditions that can
cause sudden back-wheel slippage. The ASR in
these situations automatically intervenes by re-
ducing engine output within the limit imposed by
the grip conditions, contributing significantly to the
maintenance of stability the vehicle.
WARNING
THE ASR SYSTEM IS BASED ON THE RECOGNITION OF

SPEED DIFFERENCES BETWEEN FRONT AND REAR
WHEEL. FOR THE SYSTEM TO PERFORM CORRECTLY IN
ALL CONDITIONS, THE PROCEDURE MUST BE PER-
FORMED EACH TIME A TYRE IS REPLACED EVEN IF ON-
LY ONE OF THE TYRES IS REPLACED.
FOR THE CALIBRATION OF THE ASR SYSTEM PERFORM
THE PROCEDURE BELOW.
WARNING
PRE DE - 12
THE ASR SYSTEM PREVENTS THE APPLICATION OF

HIGH SPEED ROTATION ON THE REAR WHEEL WITH THE
VEHICLE ON THE CENTRE STAND.
IT IS RECOMMENDED TO NOT INSIST WITH THE THROT-
TLE GRIP IN THIS SPECIFIC SITUATION, BECAUSE THIS
MAY CAUSE ABNORMAL STOPS AND/OR DAMAGE TO
THE CATALYSTS.
ASR System "1" deactivation button

to deactivate the ASR system, with the engine run-
ning, press the corresponding button for at least 1
second.
ASR "2" system activation icon

System active and calibrated: icon flashes when
the key is "ON", then goes off with the engine run-
ning.
ASR "3" system deactivation icon

Icon "ASR OFF": on steady with engine started,
ASR system not working or not calibrated or vol-
untarily deactivated.
ASR/ASR OFF ICON OPERATION MODE

ASR System status ICON with engine off ICON with engine on ASR working
or key "ON"
ACTIVE and calibrated "ASR" icon: 1Hz slow Icons switched off "ASR" icon: 5Hz fast
flashing flashing
ACTIVE not calibrated Icon "ASR OFF": on Icon "ASR OFF": on steady "ASR" icon: 5Hz fast
steady flashing
ASR voluntarily deactivated Icon "ASR OFF": on Icon "ASR OFF": on steady -
steady
ASR system not working Icon "ASR OFF": on Icon "ASR OFF": on steady -
steady
Programming phase (successful) - "ASR" icon: 1Hz slow flashing (then -
when the engine is started, the icons
turn off if the programming is suc-
cessful)
Programming phase (failed) Icon "ASR OFF": on steady when en- -
gine is started if the programming
has failed
PRE DE - 13
Manual calibration procedure of the ASR sys-

tem.
In order to maintain the efficiency of the ASR sys-
tem when one or both tires are replaced, a cali-
bration procedure of the ASR system must be
performed as follows on a straight flat stretch of
road:
1. With vehicle at a standstill and engine off.
2. Pull the brake lever, turn the starter switch to
"ON" and start the engine.
3. Disconnect the ASR system by pressing the

corresponding button for at least 1 second with the
engine running; The "ASR OFF" icon will be-
come steady on, initially it was off as the ASR
system had already been calibrated in the past.
4. Drive at a low speed for a few meters, until the

"ABS" indicator light stops flashing.
5. To start the programming procedure, press the
start button and the ASR button at the same time
for at least 4 seconds, until the "ASR OFF" icon
starts flashing; then release the buttons.
6. Start driving and increase the speed up to 30

km/h within 1 minute, keep the speed constant
for at least 10 seconds,
The "ASR OFF" icon switched off indicates that
the calibration was successful.
7. Stop the vehicle and shut off the engine by

turning the starter switch to the "OFF" position.
PRE DE - 14
8. If the procedure has been completed cor-

rectly, the next time the starter switch is turned
to the "ON" position, the "ASR" icon lights up
with 1Hz slow flashing (1 flash per second).
When starting the engine, the "ASR" icon turns off
and the ASR system will be ACTIVE.
9. If the procedure is NOT completed correctly,

the "ASR OFF" icon will be switched on steady.
By pressing the appropriate button, the user can
manually reactivate the ASR system by returning
it to the previously stored calibration.
WARNING
N.B.
BY TURNING THE STARTER SWITCH TO THE "ON" POSITION, THE FLASHING ASR ICON IN-
DICATES THE SYSTEM DIAGNOSIS PHASE. IF THERE IS NO FLASHING WHEN THE ENGINE IS
STARTED, THE ASR SYSTEM MAY NOT BE WORKING.
WARNING
THE ASR SYSTEM IS ACTIVATED EVERY TIME, THE STARTER SWITCH IS TURNED TO THE
"ON" POSITION.
IF DISABLED BY THE USER, THE ASR SYSTEM KEEPS THE STATE OF INACTIVITY ONLY IF
THE VEHICLE IS OFF, BY USING THE ENGINE STOP SWITCH; THE NEXT TIME THE STARTER
SWITCH IS TURNED, THE ASR SYSTEM IS AUTOMATICALLY ENABLED.
CAUTION
IT IS RECOMMENDED TO PAY PARTICULAR ATTENTION IN THE EVENT OF ACCELERATION

FROM STANDSTILL IN CONDITIONS OF LOW GRIP, ESPECIALLY IN THE FIRST METRES.
CAUTION
A POOR STATE OF MAINTENANCE OF THE TYRES CAN RESULT IN ABNORMAL OPERATION

OF THE ASR SYSTEM.
IN CASE OF REPEATED INTERVENTIONS OF THE ASR, EVEN ON ROAD SURFACES WITH
GOOD GRIP OR SMALL THROTTLE OPENINGS, IT IS NECESSARY TO CHECK FOR WEAR AND/
OR THE STATE OF INFLATION OF TYRES FIRST.
CAUTION
IT IS EMPHASISED THAT THE RIDING AUXILIARY SYSTEM CANNOT CHANGE THE PHYSICAL
LIMITS OF GRIP AND IS NOT A SUBSTITUTE FOR PROPER MANAGEMENT OF POWER, BOTH
ON STRAIGHT STRETCHES AND IN TURNS. THEREFORE, IT IS RECOMMENDED TO ALWAYS
USE THE VEHICLE WITH THE UTMOST CARE AND IN ACCORDANCE WITH THE REGULATIONS
IN FORCE.
PRE DE - 15
N.B.
THE DEVICE PREVENTS IMPRESSING ON THE REAR HIGH SPEED ROTATION WHEEL WITH
THE VEHICLE ON THE CENTRE STAND. IT IS RECOMMENDED NOT TO INSIST WITH THE
THROTTLE GRIP IN THIS PARTICULAR CONDITION.
N.B.
IN CASE OF ROAD DISCONNECTIONS THERE COULD BE SHORT ACTIVATIONS OF THE ASR
SYSTEM. SUCH EVENT APPEARS UNDER NORMAL OPERATION CONDITIONS OF THE VEHI-
CLE.
CAUTION
IN THE EVENT OF MALFUNCTION OF THE BATTERY, THE ABS - ASR SYSTEM TURNS OFF.
PRE DE - 16
INDEX OF TOPICS
TECHNICAL DATA DT
Technical Data Beverly 400 E5
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 carefully to avoid
the risk of inhaling dust produced by worn 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 spare parts may damage the vehicle.
- Use only the appropriate tools designed for this vehicle.
- Always use new gaskets, seal rings and cotter pins when reassembling.
- 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.
- Use only equipment with metric sizes for removal, service and reassembly operations. Metric bolts,
nuts and screws are not interchangeable with coupling members using English measurements. 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.
DT - 18
Beverly 400 E5 Technical Data
Vehicle identification
Identification registration numbers are made up of

a prefix and a number, stamped on the frame and
on the engine. The serial number must always be
indicated when ordering spare parts. We recom-
mend checking that the frame registration number
stamped on the vehicle corresponds with that on
the vehicle documentation.
CAUTION
PLEASE REMIND THAT ALTERING IDENTIFICATION REG-

ISTRATION NUMBERS CAN LEAD TO SERIOUS PENAL
SANCTIONS (IMPOUNDING OF THE VEHICLE, ETC.).
Frame number
It is necessary to remove the door «A» inside of
the front glove compartment to read the frame
number.
Engine number
The engine number is stamped near the rear left
shock absorber lower support.
DT - 19
VEHICLE IDENTIFICATION
Specification Desc./Quantity
Frame prefix ZAPMD2200
Engine prefix MD22M
Engine Data
ENGINE SPECIFICATIONS
Type Single cylinder 4-stroke
Engine capacity 399 cc
Bore per stroke 84.0 x 72.0 mm
Compression ratio 11,5 ± 0,5 :1
Idle speed 1600 ± 100 rpm
Timing system Four valves, single overhead camshaft, chain-driven.
Valve clearance Intake: 0.10 mm
Exhaust: 0.15 mm
Maximum power 26.0 kW at 7000 rpm
Maximum torque 37.7 Nm at 5,500 rpm
Transmission With the expandable pulley continuously variable transmission
with torque server, trapezoid belt, automatic clutch oil bath
centrifuge.
Final drive reduction gear Gear reduction unit in oil bath.
Lubrication Engine lubrication with trochoidal pump (inside the crankcase),
oil filter and pressure adjustment by-pass.
Cooling Forced coolant circulation system.
Starting Electric
Ignition Electronic, inductive, high efficiency ignition, integrated with the
injection system, with variable advance and separate H.V. coil.
Ignition advance Three-dimensional map managed by control unit
Power supply Indirect electronic injection.
Spark plug NGK / MR7BI-8
Fuel Unleaded gasoline E10 (95 R.O.N.)
Silencer Absorption-type exhaust silencer with a three-way catalytic
converter and lambda probe to the exhaust.
Emissions compliance EURO 5
DT - 20
Dimensions and mass
VEHICLE DATA
Frame Tubular and steel sheets.
Front suspension Hydraulic telescopic fork with Ø 35-mm stem.
Rear suspension Two double-acting shock absorbers, adjustable to five posi-
tions at pre-loading.
Front brake Ø 300 mm hydraulically operated disc brake controlled from RH
handlebar lever; braking assisted by ABS system.
Rear brake Ø 240 mm hydraulically operated rear disc brake controlled
from LH handlebar lever; braking assisted by ABS system.
Wheel rims type Light alloy.
Front wheel 3.00"x 16"
Rear wheel 4.00"x 14"
Front tire 120/70 16 M/C 57S
Rear tire 150/70 14 M/C 66S
Front tire pressure (with passenger) 2.2 bar (2.2 bar)
Rear tire pressure (with passenger) 2.4 bar (2.6 bar)
Kerb mass 195 kg
Maximum technically permissible weight at full load 380 kg
Battery SEALED 12V/10Ah
Capacities
CAPACITY
Engine oil 1.40 l
Transmission oil 500 cm³
Cooling system fluid 1.44 l
Fuel tank capacity 12.0 ± 0.5 litres
DT - 21
FRONT FORK OIL

Front fork oil 155 ± 2,5 cc for each stem.
Tightening Torques
N.B.
THE UNITS OF MEASUREMENT CONTAINED IN THIS CHAPTER ARE EXPRESSED IN TERMS
OF THE DECIMAL METRIC SYSTEM. IN THE CASE OF VALUES EXPRESSED USING IMPERIAL
AND US CUSTOMARY MEASUREMENT UNITS, REFER TO THE CONVERSION TABLE IN CHAP.
«SPECIFICATIONS».
FRONT SUSPENSION
FRONT SUSPENSION
Name Torque in Nm
Front mudguard - Steering tube 10.0 ± 1.0 Nm
Lower steering bearing lock-nut - Steering tube 15.0 ± 2.0 Nm
Upper steering bearing lock-nut - Steering tube 42.0 ± 2.0 Nm
fork - Front wheel axle 6.0 ± 1.0 Nm
Front mudguard (front part) - Front mudguard (rear part) 1.5 ± 0.5 Nm
Front mudguard - Steering tube 6.0 ± 1.5 Nm
Wheel axle nut - wheel axle 95.0 ± 5.0 Nm
ABS sensor - Fork 7.0 ± 1.0 Nm
Brake calliper - Fork 25 ± 1 Nm
TRANSMISSIONS AND BRAKES
DT - 22
DT - 23
DT - 24
TRANSMISSIONS AND BRAKES

Name Torque in Nm
Brake pipe retainer clamp - Engine 10.5 ± 0.5 Nm
Throttle control transmission fixing nut - Throttle body 5.5 ± 0.5 Nm
Brake pipe retainer clamp - Frame 10.5 ± 0.5 Nm
Gas transmission retainer clamp - Frame 10.0 ± 1.0 Nm
Brake pipe retainer clamp - Fork 10.5 ± 0.5 Nm
ABS control unit - ABS control unit support bracket 9.0 ± 1.0 Nm
Ground cable - ABS control unit 9.0 ± 1.0 Nm
Brake pipes - ABS control unit 18.5 ± 1.5 Nm
ABS control unit support bracket - Frame 10.5 ± 0.5 Nm
Ground cable - ABS control unit support bracket 8.5 ± 1.0 Nm
Front brake pipe - Front brake master cylinder 22.5 ± 2.5 Nm
Brake pipes bracket clamp - ABS control unit bracket 5.0 ± 1.0 Nm
Rear brake pipe - Rear brake pump 22.5 ± 2.5 Nm
Rear brake pipe - Rear brake calliper 22.5 ± 2.5 Nm
Front brake pipe - Front brake calliper 22.5 ± 2.5 Nm
REAR SUSPENSION
DT - 25
DT - 26
REAR SUSPENSION
Name Torque in Nm
Rear shock absorber - Engine 42.5 ± 2.5 Nm
Rear ABS sensor - Engine 7.0 ± 1.0 Nm
Silent block bracket - Frame 71.0 ± 4.0 Nm
Rear wheel - Rear wheel axle 113.0 ± 11.0 Nm
Rear brake calliper - Engine 47.0 ± 5.0 Nm
Mudguard frame - Engine 22.5 ± 2.5 Nm
Swingarm bushing - Frame 6.0 ± 1.0 Nm
Swingarm - Silent block bracket 98.0 ± 10.0 Nm
Swingarm - Frame 52.5 ± 2.5 Nm
Engine side swinging arm - Chassis side swinging arm 42.5 ± 2.5 Nm
Swinging arm on engine side - Engine 58.0 ± 2.0 Nm
Rear shock absorber - Chassis 42.5 ± 2.5 Nm
Right rear shock absorber bracket - Silencer support arm 22.5 ± 2.5 Nm
ELECTRICAL SYSTEM
DT - 27
DT - 28
ELECTRICAL SYSTEM
Name Torque in Nm
MIUG4 control unit connection retainer clamp - Throttle body 7.0 ± 1.0 Nm
Earth braid - Engine 8.5 ± 1.0 Nm
Starter motor ground - Starter motor 12.0 ± 1.0 Nm
Positive cable connection - Starter motor 7.0 ± 1.0 Nm
ENGINE
DT - 29
DT - 30
ENGINE
Name Torque in Nm
Pressure reducer counterweight retainer screw 7 ÷ 8.5 Nm
Water pump impeller driving joint 13 ÷ 15
Cylinder head nut (TIGHTENING) 9 ÷ 11 (Tighten to 9 ÷ 11 Nm then proceed for 270.0° ±5.0° of
rotation)
M12x1.25 gear clutch shaft retainer nut 95 ÷ 105
Final reduction cover screws 24 ÷ 27
Screws fixing cylinder head to crankcase 20 ÷ 24
Impeller on the pump shaft 4÷6
Bearing lock screw 9 ÷ 11
Oil relief screw 15 ÷ 17
Reduction unit oil drainage screw 15 ÷ 17
Driven pulley nut 50 ÷ 60
Nut M14x1.5 securing the driving pulley 120 ÷ 130
Locking the chain tensioner support hood 5÷6
Mount the locking chain tensioner with 2 screws 11 ÷ 13
Containing plate retainer screws 4.5 ÷ 5.5
Timing system gear sprocket fixing screw 11 ÷ 15
Cylinder head nut (PRE-TIGHTENING) 6÷8
Minimum oil pressure sensor 12 ÷ 14
LOCKS
DT - 31
LOCKS
Name Torque in Nm
Saddle opening actuator support bracket - Frame 6.0 ± 1.0 Nm
Saddle-lock - Helmet compartment 6.0 ± 1.0 Nm
Glove-box opening rocker - Frame 6.0 ± 1.0 Nm
Overhaul data
Assembly clearances
Cylinder - piston assy.
DT - 32
PISTON-CYLINDER COUPLING CATEGORY

Name Initials Cylinder Piston Play on fitting
cylinder - piston M (84.010 ÷ 84.017)mm (83.953 ÷ 83.960)mm (0.050 ÷ 0.064)mm
cylinder - piston N (84.017 ÷ 84.024)mm (83.960 ÷ 83.967)mm (0.050 ÷ 0.064)mm
cylinder - piston O (84.024 ÷ 84.031)mm (83.967 ÷ 83.974)mm (0.050 ÷ 0.064)mm
cylinder - piston P (84.031 ÷ 84.038)mm (83.974 ÷ 83.981)mm (0.050 ÷ 0.064)mm
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.
- Check that the head coupling surface is not worn
or misshapen.
- Pistons and cylinders are classified according to
diameter. The coupling is carried out in pairs (M-
M, N-N, O-O, P-P).
Characteristic
Maximum allowable run-out:
0.001 in 0.05 mm
Piston rings
- 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.
- Check the clearance upon mounting (A) of the
bands:
N.B.
MEASURE THE CLEARANCE BY INSERTING THE BLADE
OF THE FEELER THICKNESS GAUGE FROM THE SECOND
SEAL SIDE.
ASSEMBLY CLEARANCE OF BANDS - SEAL RINGS

DENOMINATION DIMENSIONS ASSEMBLY CLEARANCES (A)
1st compression ring 84 x 1 mm 0.10 ÷ 0.30 mm
Oil scraper ring 84 x 1.5 mm 0.35 ÷ 0.55 mm
Oil scraper ring 84 x 2.5 mm 0.25 ÷ 0.55 mm
Crankcase - crankshaft - connecting rod
CRANKSHAFT
Titolo Durata/Valore Testo Breve (< 4000 car.) Indirizzo Immagine
Crankshaft Axial clearance between
crankshaft and connecting rod
DT - 33
Axial clearance between crankshaft and connecting rod
AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD

Name Code Dimensions Assembly clearance
Transmissionside half-shaft A 0.72 (+0; -0.002) in 18.4 D=0.007÷0.01 in
(+0; -0.05) mm (0.20÷0.50 mm)
Flywheel-side halfshaft B 0.72 (+0; -0.002) in 18.4 D= 0.008÷0.019 in
(+0; -0.05) mm 0.20÷0.50 mm
Connecting rod C 0.7 (-0.003; -0.005) in D= 0.007÷0.019 in
19 (-0.10; -0.15) mm 0.20÷0.50 mm
Spacer tool E 2.20 (+0; +0.001) in 56 D= 0.007÷0.019 in
(+0; +0.05) mm 0.20÷0.50 mm
DT - 34
Characteristic
Crankshaft-crankcase axial clearance (H)
0.15 ÷ 0.43 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).
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:
0.001 in 0.05 mm
- In case of faults, replace the head.

- Check the sealing surfaces for the exhaust mani-
fold.
- Check that the camshaft and the rocker pin ca-
pacities exhibit no wear.
- Check that the head cover shows no signs of
wear.
- Check that there is no cooling liquid leakage from
the seals.
DT - 35
- 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.
Measure the camshaft bearing seats and rocking

lever support pins with a bore meter
HEAD BEARINGS
bearing «A» Ø(0.511÷0.512)in Ø(13.000÷13.018)mm
bearing «B» Ø(0.708÷0.709)in Ø(18.000÷18.021)mm
bearing «C» Ø(1.456÷1.457)in Ø(37.000÷37.025)mm
DT - 36
Measure the unloaded spring length
Characteristic
Standard length
(1.602)in (40.7)mm
Allowable limit after use:
(1.543)in (39.2)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:
(0.039÷0.051)in (1 ÷ 1.3)mm
Limit allowed:
(0.062)in (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.
- Measure the diameter of the valve stems in the

three positions indicated in the diagram.
STANDARD DIAMETER
Intake: (0.1951÷0.1957)in (4.957÷4.972)mm
Exhaust: (0.1942÷0.1948)in (4.935÷4.950)mm
MINIMUM DIAMETER PERMITTED

Intake: (0.194)in (4.942)mm
Exhaust: (0.192)in (4.92)mm
- Calculate the clearance between the valve and the valve guide.
DT - 37
- 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 allowed:
(0.0007)in (0.02)mm
- Check the oscillation 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
Limit allowed:
(0.007)in (0.2)mm
Measure the valve guide.
Characteristic
Valve guide:
0.196(+0 +0.0004)in 5(+0 +0.012)mm
- After measuring the valve guide diameter and the

valve stem diameter, check clearance between
guide and stem.
INTAKE
Standard clearance: (0.001÷0.002)in (0.028÷0.055)mm
Limit allowed: (0.003)in (0.08)mm
EXHAUST
Standard clearance: (0.001÷0.003)in (0.05÷0.077)mm
DT - 38
Limit allowed: (0.003)in (0.1)mm
- Check that there are no signs of wear on the

mating surface with the set screw articulated ter-
minal.
- 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 MATING SURFACE, DO NOT ROTATE 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
Camshaft check: Standard diameter Bearing A Ø: (1.454÷1.455)in (36.95÷36.975)mm
Camshaft check: Standard diameter Bearing B diameter: (0.707-0.708)in (17.966-17.984) mm
MINIMUM DIAMETER PERMITTED

Camshaft check: Minimum diameter permitted Bearing A Ø: (1.454)in (36.94)mm
Camshaft check: Minimum diameter permitted Bearing B diameter: (0.7069)in (17.957)mm
DT - 39
-Using a gauge, measure the cam height.
STANDARD HEIGHT
Camshaft check: Wear limit Exhaust: (1.178)in (29.945)mm
Camshaft check: Wear limit Intake: (1.218)in (30.948)mm
Camshaft check: Standard height Intake: (1.220±0.001)in (31.008±0.03)mm
Camshaft check: Standard height Exhaust: (1.181±0.001)in (30.005±0.03)mm
Check the axial clearance of the camshaft
CAMSHAFT AXIAL CLEARANCE

Camshaft check: Standard axial clearance: (0.003÷0.016)in (0.09÷0.41)mm
- Measure the external diameter of the rocking lever pins

- Check the rocker pins do not show signs of wear or scoring.
- Measure the internal diameter of each rocker
DT - 40
Check there are no signs of wear on the pad from contact with the cam and on the jointed adjustment
plate.
DIAMETER OF PINS AND ROCKING LEVERS

Rocking lever inside diameter: Standard diameter (C) Ø(0.512÷0.513)in Ø(13.015÷13.035)mm
Rocking lever pin diameter: Standard diameter (D) Ø(0.510÷0.511)in Ø(12.977÷12.985)mm
Nominal clearance (0.001÷0.002)in (0.030÷0.058)mm
Maximum clearance allowed (0.003)in (0.08)mm
DT - 41
Slot packing system
Characteristic
Compression ratio
11,5 ± 0,5 :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.
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 400 SHIMMING

Name Measure A Thickness
Shimming 0.475 ÷ 0.575 mm 0.2 mm
Shimming 0.325 ÷ 0.475 mm 0.3 mm
Shimming 0.225 ÷ 0.325 mm 0.4 mm
DT - 42
INDEX OF TOPICS
TOOLING TOOL
Tooling Beverly 400 E5
ATTREZZATURA SPECIFICA
Stores code Description
001330Y Tool for fitting steering seats
001467Y014 Calliper to extract ø 15-mm bearings
006029Y Punch for fitting steering bearing on the

steering tube
020004Y Punch for removing steering bearings

from headstock
020055Y Wrench for steering tube ring nut
020128Y Piston fitting ring
TOOL - 44
Beverly 400 E5 Tooling

020115Y punch ø 18
020151Y Air heater
020193Y Oil pressure gauge
020244Y punch ø 15
020271Y Tool for removing-fitting silent bloc
020263Y Driven pulley assembly sheath
TOOL - 45

020306Y Punch valve seal rings fitting
020329Y Mity-Vac vacuum pump
020331Y Digital multimeter
020332Y Digital rpm indicator
020335Y Magnetic mounting for dial gauge
TOOL - 46

020359S 42 x 47 mm Adaptor
020358Y 37 x 40 mm Adaptor
020360S 52 x 55 mm adaptor
020363Y 20-mm guide
020375Y 28 x 30 mm adaptor
020376Y Adaptor handle
020382Y Valve cotters equipped with part 012 re-

moval tool
TOOL - 47

020382Y011 adapter for valve removal tool
020412Y 15-mm guide
020423Y Driven pulley lock wrench
020424Y Driven pulley roller casing fitting punch
020426Y Piston fitting fork
020428Y Piston position check mounting
TOOL - 48

020431Y Valve oil seal extractor
020434Y Union for oil pressure measurement
020439Y 17-mm guide
020442Y Pulley lock wrench
020444Y Tool for installing/removing clutch on/

from driven pulley
020454Y Tool for fitting the pin snap rings
TOOL - 49

020456Y Ø 24 mm adaptor
020467Y Flywheel extractor
020477Y Adapter 37 mm
020480Y Fuel pressure measurement kit
020483Y 30-mm guide
020487Y Fork oil seal extractor
TOOL - 50

020489Y Hub cover support stud bolt kit
020627Y Flywheel lock tool
020648Y Single battery charger
020917Y Driven pulley stop
020922Y Diagnosis Tool
020924Y Bluetooth per Strumento di Diagnosi

PADS
TOOL - 51

021017Y EOBD E5 diagnostics cable
TOOL - 52
INDEX OF TOPICS
MAINTENANCE MAIN
Maintenance Beverly 400 E5
MAINTENANCE ICON OPERATION

This function indicates the scheduled mainte-
nance interventions. For each time the key is
turned to "ON", once the instrument panel has per-
formed the initial check, if the value of the remain-
ing kilometres until the next intervention is less
than 300 Km (186.41 mi), the indicated icon will
flash for 5 seconds. Once the service intervention
mileage is reached, each time the key is turned to
"ON", the icon remains lit steadily until it is reset.
MAINTENANCE ICON RESETTING

The maintenance icon is reset by pressing the
SET key on the instrument cluster for more than 5
seconds, while turning the key to the "ON".
During the first 5 seconds, the digital display will
not generate any signal; during the next 5 sec-
onds, the maintenance icon will flash with a fre-
quency of 1 Hz.
If the SET key is released before the 5 seconds,
the scheduled service is not reset
CAUTION
THE MAINTENANCE ICON RESET PROCEDURE MAY ON-

LY BE PERFORMED WHEN THE VEHICLE IS AT A STAND-
STILL (SPEED = 0 Km/h).
SHORT PRESS/PROLONGED PRESS

SHORT PRESS (PRESS AND RELEASE) LESS THAN 0.5 SECONDS.
PROLONGED PRESS (PRESS AND HOLD) BETWEEN 1 AND 5 SECONDS.
INPUT, CONFIRM AND TIMEOUT TIMES LONGER THAN 5 SECONDS.
Maintenance chart
SCHEDULED MAINTENANCE TABLE

I:CHECK AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY.
C: CLEAN, R:REPLACE, A:ADJUST, L:LUBRICATE
* Clean more frequently in cases of intensive use on gravel roads.
km x 1,000 (mi x 1,000) 1 (0.6) 10 (6.2) 20 30 40 50 EVERY 12 EVERY 24

(12.4) (18.6) (24.8) (31.0) MONTHS MONTHS
Safety blocks I I I I I I
Spark plug R R
Centre stand L L L L L L L
Drive belt R R
MAIN - 54
Beverly 400 E5 Maintenance
km x 1,000 (mi x 1,000) 1 (0.6) 10 (6.2) 20 30 40 50 EVERY 12 EVERY 24

(12.4) (18.6) (24.8) (31.0) MONTHS MONTHS
Throttle control I I I I I I I I
Complete roller housing I I
Diagnosis by tool I I I I I I I I
Air filter * R R R R R
CVT Filter * C C C C C
Engine oil filter R R R R R R R R
Valve clearance I I
Electrical system and battery I I I I I I
Braking system I I I I I I I I
Coolant I I I I I I I R
Brake Fluid I I I I I I I R
Engine oil R R R R R R R R
Hub oil R R R I I
Headlight direction adjustment I I I I I
Brake pads I I I I I I I
Sliding shoes / CVT rollers R R
Tire pressure and wear I I I I I I I I
Vehicle road test I I I I I I I I
Suspensions I I I I I I I I
Steering A I I I I I I I
Labour time (minutes) 70 70 130 70 130 70 40 100
N.B.
AT EACH SCHEDULED MAINTENANCE MUST BE VERIFIED WITH THE DIAGNOSTIC TOOL IF
THERE ARE ERRORS AND THE IF THE PARAMETERS ARE CORRECT.
ENSURE THAT THE VEHICLE CALIBRATION IS UP TO DATE AFTER UPDATING THE DIAGNOS-
TIC TOOL.
CAUTION
AFTER THE PROVIDED MAINTENANCE PROGRAM IS INDICATED TO PROCEED WITH THE
MAINTENANCE OF THE VEHICLE STARTING FROM THE SERVICE OF 5,000 Km (3,106 mi) OR
5 MONTHS.
Recommended products
Piaggio Group recommends the use of prod-

ucts from its Castrol official partner for the
scheduled maintenance of its vehicles.
Only use lubricants and fluids which meet or ex-
ceed the performance characteristics specified.
This also applies when topping up only.
TABLE OF RECOMMENDED PRODUCTS

Product Description Specifications
Engine oil 5W -40 Synthetic-based lubricant for four-stroke SAE 5W-40; JASO MA, MA2; API SL;
engines. ACEA A3
Transmission oil 80W-90 Lubricant for gearboxes and transmis- SAE 80W-90 API GL-4
sions.
Anti-freeze liquid, ready to use, colour red Ethylene glycol antifreeze liquid with or- ASTM D 3306 - ASTM D 4656 - ASTM D
ganic inhibition additives. Red, ready to 4985 - CUNA NC 956-16
use.
DOT 4 brake fluid Synthetic brake fluid. SAE J 1703; FMVSS 116; ISO 4925; CU-
NA NC 956 DOT4
Front fork oil Specific front fork oil SHOWA SHOWA SS-8G.
Lubricant grease Lithium and medium fibre yellow brown ISO L-X-BCHA 3 - DIN 51 825 K3K -20
coloured grease suitable for various
uses.
Water repellent spray grease Water repellent pouring calcium spray White, soap base spray grease with NLGI
grease. 2 Calcium complex; ISO-L-XBCIB2
MAIN - 55
Level check
Engine cooling is forced liquid circulation. The

coolant is composed of a mix of 50% demineral-
ised water and an ethylene glycol-based anti-
freeze with corrosion prevention components. The
coolant included with the scooter is already mixed
and ready for use.
For proper functioning of the engine, ensure that
the temperature of the coolant is maintained at
about 90°C.
When all the bars and the icon on the coolant level
indicator start flashing, stop the engine immedi-
ately, let it cool down and check the liquid level.
Check the fluid with cold engine according to the
scheduled maintenance table, in the way shown
below.
Bring the vehicle in vertical position on the stand

and open the front case.
Remove the expansion tank cap «A» rotating it

anticlockwise.
MAIN - 56
Look on the visible part of the coolant reservoir and

check that the fluid level is always the MIN and
MAX level marks.
Top up with fluid if the level is near the minimum
mark. If the level of the fluid is not correct, top it up.
This should be done when the engine is cold. If the
coolant needs to be topped up frequently or the
coolant reservoir is completely dry, check the cool-
ing system to determine the cause of the problem.
WARNING
TO AVOID THE RISK OF SCALDING, DO NOT UNSCREW

THE EXPANSION TANK COVER WHILE THE ENGINE IS
STILL HOT.
WARNING
YOU MUST MAKE SURE THE FLUID NEVER EXCEEDS

THE MAXIMUM LEVEL INDICATED SO AS TO AVOID IT
OVERFLOWING AND CAUSING DAMAGE WHILE THE
SCOOTER IS MOVING.
TO ENSURE CORRECT ENGINE OPERATION, KEEP THE
RADIATOR GRILLE CLEAN.
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 pads.
MAIN - 57
Top-up
To top-up the brake fluid, proceed as follows:

place the vehicle on the centre stand and remove
the rear-view mirrors by unscrewing them from
their seats.
Unscrew the fixing screw of the rear handlebar
cover, located on the left side of the vehicle.
Unscrew the fixing screw of the rear handlebar

cover, located on the right side of the vehicle.
Gently press the front handlebar cover to the in-

side and release the rear handlebar cover from its
locks.
Remove the front handlebar cover.
MAIN - 58
Unscrew the two lever cover fixing screws, from

the right and left side of the vehicle.
- Remove the lever cover from both sides of the

vehicle.
Unscrew the lower fixing screws of the rear han-

dlebar cover, one from the right side and one from
the left side of the vehicle.
Unscrew the upper fixing screws of the rear han-

dlebar cover, one from the right side and one from
the left side of the vehicle.
MAIN - 59
Unscrew the central fixing screw of the rear han-

dlebar cover.
Slightly move the rear handlebar cover and re-

lease the instrument panel connector.
Remove the rear handlebar cover.
Unscrew the two fixing screws of the brake pump,

right or left.
MAIN - 60
Remove the brake pump cap and restore the rec-

ommended brake fluid level using the specified
product.
CAUTION
ONLY USE DOT 4-CLASSIFIED BRAKE FLUID.
CAUTION
BRAKE FLUID IS HYGROSCOPIC; THAT IS, IT ABSORBS
MOISTURE FROM THE SURROUNDING AIR. IF THE CON-
TENT OF MOISTURE IN THE BRAKE FLUID EXCEEDS A
CERTAIN VALUE, BRAKING WILL BE INEFFICIENT.
NEVER USE BRAKE LIQUID FROM OPEN OR PARTIALLY
USED CONTAINERS.
UNDER NORMAL CLIMATIC CONDITIONS, REPLACE FLU-
ID AS INDICATED IN THE SCHEDULED MAINTENANCE
TABLE.
CAUTION
BRAKE CIRCUIT FLUID IS HIGHLY CORROSIVE: DO NOT
LET IT COME INTO CONTACT WITH PAINTED PARTS.
CAUTION
AVOID CONTACT OF BRAKE FLUID WITH EYES, SKIN,

AND CLOTHING. IN CASE OF ACCIDENTAL CONTACT,
RINSE WITH WATER.
N.B.
SEE THE BRAKING SYSTEM CHAPTER WITH REGARD TO
THE CHANGING OF BRAKE FLUID AND THE BLEEDING
OF AIR FROM THE CIRCUITS.
Anti-evaporation system
The vehicle is equipped with the "Canister", main component of the system for the control of evaporative
emissions, compliant with the current standards.
A. Fuel pump
B. Fuel tank
C. Two-way fuel vapour ventilation valve
D.Canister
E.Air purge pipe into atmosphere
F.One-way electronic fuel vapour purge control
valve (controlled by ECU)
G. Vacuum fitting
H. Throttle body
I. Air induction fitting
L. Injector
MAIN - 61
The evaporative emissions control system is located on the rear side of the vehicle.
Key:
1 Canister
MAIN - 62
2 Bleeder pipe
3 Pipe for connecting the canister to the inlet fitting
4 Canister valve
5 Pipe for connecting the fuel tank to the canister
6 Breather valve
Removing system components
Remove the helmet compartment and the side fairings to gain access to the components of the evap-
orative emissions control system.
MAIN - 63
Refitting system components

Fasten the canister to the special pin on the frame,
making sure to position the purge pipe fitting down-
ward.
Upon reassembling the components, use caution

when connecting the pipes to the canister.
1. canister - insertion coupling connection pipe.

2. tank - canister connection pipe.
3. Bleeder pipe.
MAIN - 64
Refit the components by properly inserting the pipes and securing them with new metal clamps.
CAUTION
TAKE CARE TO ENSURE THE PROPER DIRECTION OF THE COMPONENTS' INSTALLATION: IF

INSTALLED IN REVERSE, THEY COULD COMPROMISE THE FUNCTIONALITY OF THE ENTIRE
EVAPORATING SYSTEM.
After having installed the components, secure the pipes with new ties.
Upon refitting the canister valve, observe the di-

rection of the arrow toward the engine.
MAIN - 65
Ensure the correct orientation of the breather

valve, with the writing "TANK/RESERVOIR"
placed on the side shown in the figure.
If you detect different pressures, replace the valve.
Characteristic
Opening pressure
110 mbar
Canister inspection
The canister is essential to treat the hydrocarbons

present in the volume of gas that escapes from the
tank when there is an increase in internal pressure
(tank heating induced by the cooling radiator, by
the motor or by the external environment).
Although the amount of hydrocarbons coming
from the tank is small enough to avoid the satura-
tion of the canister, it is necessary to regenerate
the activated carbon by means of a reversed flow
of ambient air sucked by the engine.
These vacuums of pollution and carbon regener-
ation take place at each cycle of use of the vehicle.
To control the canister, it is necessary to proceed with its removal while keeping the 2 pipes connected.
• Shake the Canister and make sure there is no noise.

• Using a compressed air gun, blow alternately in 3 ducts and make sure that pressure does
not build inside the canister.
• Check that the air flow is kept free and that no carbon residues escape out of any pipe.
If you detect noise, clogging or loss of carbon, replace the canister.
MAIN - 66
INDEX OF TOPICS
ELECTRICAL SYSTEM ELE SYS

Electrical system Beverly 400 E5
Instrument panel
Key:
A = Left hand turn signal indicator lamp;
B = Immobilizer LED
C = Engine management system warning lamp (MIL)
D = High beam lights on indicator lamp
E = Low engine oil pressure warning lamp
F = ABS warning lamp
G = Right turn indicator warning light
H= Digital display
DIGITAL DISPLAY
ELE SYS - 68
Beverly 400 E5 Electrical system
Key:
A = Heated accessory icon and heating level management provision (optional - requires both PMP3
control units and heating modules to be present)
B = Fuel gauge with fuel symbol
C = Icon for SMS message on smartphone
D = Multifunctional panel
E = Ice hazard icon
F = Ambient temperature indicator
G = ASR system activation icon
H = ASR system deactivation icon
I = Side stand icon
L = Tachometer
M = Smartphone multimedia profiles connection

icon (for further details, please consult the app
manual)
N = Clock
O = Total/partial odometer
P = Icon for missed call on the smartphone
Q = Coolant temperature gauge
ELE SYS - 69
R = Icon for the connection between the smart-

phone PIAGGIO app and the PMP3 control unit on
the vehicle:
• if it is steady, the application commu-

nicates with the ECU;
• if it flashes, the smartphone and PMP3
control unit pairing is being performed.
S = Tyre low pressure icon provision (currently un-

available on this version)
T = Smartphone battery level icon

U = Icon for the scheduled maintenance service to
be performed
V = SET button for adjustments (clock, display
backlight)
Z = MODE button for display on the multifunctional
panel and measurement unit conversion on the
digital display
X = Speedometer
Y = Engine start inhibited icon
DIGITAL DISPLAY BACK-LIGHT COLOUR

CHANGE
To change the digital display back-light colour,
with the engine started and the ignition switch to
"ON" position, proceed as follows:
• keep the SET button on the instrument

panel pressed and at the same time
press two consecutive times on the
MODE button; the back-light will switch
to another colour.
WARNING
FOR SAFETY REASONS, THE BACK-LIGHT COLOUR ON

THE DIGITAL DISPLAY CAN BE CHANGED ONLY WITH
THE VEHICLE AT A STANDSTILL.
ELE SYS - 70
MAINTENANCE ICON OPERATION

This function indicates the scheduled mainte-
nance interventions. For each time the key is
turned to "ON", once the instrument panel has per-
formed the initial check, if the value of the remain-
ing kilometres until the next intervention is less
than 300 Km (186.41 mi), the indicated icon will
flash for 5 seconds. Once the service intervention
mileage is reached, each time the key is turned to
"ON", the icon remains lit steadily until it is reset.
AMBIENT TEMPERATURE INDICATION WITH

ICE HAZARD ICON
Each time the key is turned to "ON", the digital dis-
play will show the ambient temperature in ° C or in
° F. If the ambient temperature is less than 3°C
(37.4°F), the digital display indicates with the spe-
cific symbol the potential presence of ice on the
road. In such conditions, it is recommended to
drive carefully.
SIDE STAND ICON

The stand icon lights up when the side stand is
open.
In this state, the engine start is inhibited. Open-
ing the side stand with the engine started cau-
ses the engine to stop.
CAUTION
OPENING THE SIDE STAND INHIBITS THE ENGINE START

OR, WITH THE ENGINE STARTED, CAUSES THE ENGINE
TO STOP. TAMPERING WITH THIS SAFETY FUNCTION
MAY CAUSE PERSONAL INJURY AND DAMAGE TO THE
VEHICLE.
ELE SYS - 71
In case of inhibited engine start, the specific icon

on the digital display will also light up.
Starting can be also inhibited with the engine stop
switch (RUN-OFF) set to "OFF".
MULTIFUNCTIONAL PANEL AND TOTAL/PAR-

TIAL ODOMETER
The vehicle is equipped with the MODE button on
both the instrument cluster and on the handlebar
to allow browsing within the multifunctional panel
and selecting the odometer type.
N.B.
FOR VEHICLES EQUIPPED WITH HEATED ACCESSORY
CONTROL UNIT (OPTIONAL), THE MODE BUTTON ON
THE HANDLEBAR MANAGES THE HEATING LEVELS AND
NO LONGER ACTS AS THE MODE BUTTON ON THE IN-
STRUMENT PANEL.
SHORT PRESS/PROLONGED PRESS

SHORT PRESS (PRESS AND RELEASE) LESS THAN 0.5 SECONDS.
PROLONGED PRESS (PRESS AND HOLD) BETWEEN 1 AND 5 SECONDS.
INPUT, CONFIRM AND TIMEOUT TIMES LONGER THAN 5 SECONDS.
By briefly pressing the MODE button, the following

information can be viewed cyclically on the multi-
functional panel:
• Maximum speed
• Average speed
• Current consumption
• average consumption
• Remaining life (kilometres/miles)
• Battery charge state
ELE SYS - 72
By keeping the MODE button pressed, upon its

release, the multifunctional panel will display the
current consumption.
By briefly pressing twice on the MODE button, the

following information can be viewed cyclically on
the digital display:
• Trip A (partial odometer A)

• Trip B (partial odometer B)
• TOTAL (total odometer)
While viewing the selected function, to reset the

stored values, keep the MODE button pressed for
more than 5 seconds.
DIGITAL DISPLAY MEASUREMENT UNIT CON-

VERSION (Km-mi, l-gal, °C-°F)
• With the ignition switch turned to

"OFF", press and hold the MODE but-
ton on the instrument cluster and si-
multaneously turn the ignition switch to
"ON";
• release the button. The icons "mi",
"km", "°C", "°F" will flash;
• briefly press the MODE button, until the
desired icon is displayed (steady);
• press and hold the MODE for at least 1
to 5 seconds to change the unit of
measurement;
• the consumption measurement unit
will automatically change when "Km"
or "mi" is selected.
N.B.
THE MEASUREMENT UNIT CONVERSION CAN TAKE
PLACE ONLY WITH THE VEHICLE AT A STANDSTILL.
ELE SYS - 73
To set or adjust the time, with vehicle running or

with key inserted in «ON» position, do the follow-
ing:
• press and hold the SET button on the

instrument cluster for at least 5 sec-
onds and then release the button; the
hour value "hh" starts flashing;
peatedly to set the correct hour value;
press and hold the SET button to cycle
the hour value rapidly;
rent value, if no changes were made) -
the minutes value «mm» now starts
flashing;
peatedly to set the correct minutes val-
ue; press and hold the SET button to
cycle the minutes value rapidly;
rent value, if no changes were made).
If the SET button is not pressed for a period ex-

ceeding 5 seconds at any time during this proce-
dure, the system exits clock setting mode.
WARNING
FOR SAFETY REASONS THE TIME SETTING IS ONLY

POSSIBLE WITH THE VEHICLE AT A STANDSTILL.
WARNING
ELE SYS - 74
DISCONNECTING THE BATTERY CABLES WILL RESULT

IN A RESET OF THE CLOCK
Multimedia System PMP-PIAGGIO MIA

Download and install the specific «PIAGGIO» app
from the Play Store or Apple Store on your smart-
phone.
The procedure for pairing the smartphone - PMP -

PIAGGIO MIA Multimedia system and the entire
multimedia content will be managed with the CON-
NECTIVITY button on the handlebar.
PAIRING PROCEDURE Smartphone - Multime-

dia System PMP-PIAGGIO MIA
The vehicle is equipped with the "Piaggio MIA"
control unit that communicates with the smart-
phone via Bluetooth. Using the specific "Piaggio"
application that can be installed on the smart-
phone, it is possible to exchange data with the
vehicle and manage multimedia content.
Once the connection is established correctly be-
tween the control unit and the smartphone, the
following functions can be directly managed on the
digital display of the vehicle:
• manage phone calls;

• manage audio playback;
• SMS notifications management.
To enable the functions of the multimedia system,

it is necessary to pair the device on the vehicle with
the smartphone performing the following proce-
dure:
- With the starter switch in "OFF" position,
keep the CONNECTIVITY button on the right
side of the handlebar pressed;
- Turn the starter switch to "ON" while continu-
ing to keep the CONNECTIVITY button on the
ELE SYS - 75
right side of the handlebar pressed and wait for

the PMP-PIAGGIO MIA Multimedia System
icon to flash on the digital display;
- Release the button as soon as the "PMP-PIAGGIO MIA Multimedia System" icon starts flashing;
- At this point enable the Bluetooth search on your smartphone;
- Select the "PMP3-XXXX" device and, if requested, type the password "0000" or answer "yes" to
the pairing request message that will appear on the smartphone screen to complete the Smartphone -
Piaggio MIA pairing.
- Once the pairing has been successfully completed, the icon will remain lit steadily.
N.B.
IF SMARTPHONES WITH AN ANDROID OPERATING SYSTEM ARE USED, THE "PIAGGIO MIA"
SYSTEM WILL BE VISIBLE TWICE IN THE SEARCH SCREEN FOR BLUETOOTH DEVICES. IN
THIS PAIRING PHASE, THE ONE WITH THE HEADPHONE OR HEADSET ASSOCIATED ICON
MUST BE SELECTED.
For specific information about the pairing of
the "Piaggio MIA" system and for any differen-
ces in the procedure depending on the type of
smartphone used, please refer to the user
manual included in the "PIAGGIO" app.
Please note that the installation and connec-
tion of the app are ESSENTIAL for using the
system.
The app manual with specific information for
using the system is available by visiting the
site
www.app.piaggio.com
The paired device will be present in the list of
paired devices. Wait for the "Piaggio MIA" system
to automatically connect the smartphone. DO NOT
force the connection from the smartphone.
When requested, allow phone book and notifi-
cations sharing. These authorizations are re-
quired to manage calls from the handlebar and
view the SMS reception notification.
THE CONNECTION BETWEEN THE SMART-
PHONE AND VEHICLE WILL BE SIGNALLED
ELE SYS - 76
BY THE LIGHTING OF THE PHONE HEADSET

ICON ON THE DIGITAL DISPLAY. FOR A DE-
TAILED DESCRIPTION OF THE SYSTEM'S OP-
ERATING MODES, REFER TO THE "PIAGGIO"
APP MANUAL.
The PMP3 - PIAGGIO MIA Multimedia System in addition to the classic connectivity functions, music
management, etc ... allows you to use your Smartphone as a remote control for the following
functions:
• "Bike finder" that allows to recognize your vehicle by the flashing of the turn indicators.
• "Follow me home" that allows to keep the low beam light on for a predefined time after the
engine is switched off.
For more details about the operation, read the instructions described directly in the APP.
Lights list
This section lists the bulb types required for the

vehicle's equipment.
BULBS
1 High beam / low beam bulb Type: LED
Quantity: 2
2 Front side light bulb Type: LED
Quantity: 2
3 Front/Rear turn indicator bulb Type:LED
Quantity: 4
4 Rear tail light bulb Type: LED
Quantity: 2
5 Stop light bulb Type: LED
Quantity: 1
6 Licence plate light bulb Type: LED
Quantity: 1
7 Helmet compartment light bulb Type: Cylindrical C5W
Quantity: 1
Power: 12V - 5W
ELE SYS - 77
Fuses
The electrical system has nine protection fuses

and one main fuse, situated near the battery.
To access the main fuses, it is necessary to lift the
saddle and remove the battery cover as described
in the section "Battery".
CAUTION
BEFORE REPLACING THE BLOWN FUSE, TRY TO ELIMI-

NATE THE FAULT THAT HAS CAUSED IT TO BLOW. NEV-
ER TRY TO REPLACE A FUSE USING DIFFERENT MATE-
RIAL (FOR EXAMPLE 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
THE SYSTEM CAN CAUSE MALFUNCTIONING AND RISK
OF FIRE.
MAIN FUSES
The location and characteristics of the nine main
fuses on the vehicle, situated in the specific fuse
holder, are indicated in the table.
MAIN FUSES
1 Fuse 1 Capacity: 5A
Protected circuits: battery-powered, lights relay, instru-
ment cluster, "Piaggio MIA" PMP3 device, helmet com-
partment light.
2 Fuse 2 Capacity: 7.5 A
Protected circuits: battery-powered, diagnostic socket,
electric fan relay, electric fan, hazard warning lights de-
vice (blinker).
Protected circuits: battery-powered, injection loads re-
lay, canister valve, HV coil, "Keyless" system control
unit, logo backlight on instrument cluster, engine control
unit.
ELE SYS - 78
Protected circuits: battery-powered, electronic top-box
provision, accessory provision.
Protected circuits: power supply under starter switch,
lights relay, "Keyless" system control unit, ABS control
unit, engine control unit, injection loads relay, tip over
sensor.
instrument cluster, stop buttons, brake lights, front and
rear daylight running lights, starter button, hazard warn-
ing lights device and button (blinker), licence plate light.
Headlight switch (passing), USB port, diagnostic socket,
electric top-box provision, accessory provision, "Piaggio
MIA" PMP3 device.
Protected circuits: battery-powered, starter switch,
fuses 5, 6, 7.
Protected circuits: battery-powered, ABS control unit.
MAIN FUSE
The location and characteristics of the main fuses
on the vehicle are indicated in the table.
For replacement, contact an Authorised Service
Centre.
MAIN FUSE
1 Fuse No. 10 Capacity: 30A
Protected circuits: Vehicle main fuse.
The relays are located in the fuse box under the

saddle.
RELAY
1 Relay no. 1 Circuits: Injection loads.
2 Relay no. 2 Circuits: electric fan.
3 Relay no. 3 Circuits: Lights.
ELE SYS - 79
Duplication of keys / remote controls
Procedure for the duplication of the remote

control for "Piaggio KeyLess" system.
A= Remote control
B= Master-Key
1. Check the initial conditions:
1.1 Battery voltage higher than > 12V,
1.2 It is necessary to have the Master-Key availa-
ble
1.3 It is necessary to have all remote controls to
be coded (including those already coded before
the procedure),
1.4 It is necessary to connect the PADS diagnosis
tool to the OBD connector of the vehicle, using a
specific tool.
Specific tooling
020922Y Diagnosis Tool
021017Y EOBD E5 diagnostics cable
2. Start duplication procedure before entering
Keyless Self-diagnosis using PADS:
2.1 Ignition key on "OFF",
2.2 Press the ignition key and at the same time
approach the master key (mechanical key) to the
Keyless control unit. (*)
2.3 Following the flashing of the hazard warning
lights, the ignition key can be turned to "ON" (**)
(*) The master key is equipped with an integra-
ted transponder and must be approached to
the inner side leg shield back plate at the top
left where the Keyless control unit is situated.
(**) From the moment the selector is turned to
the "ON" position, the Remote Control Pro-
gramming procedure must be started within
120 seconds (description in step 3. Otherwise,
the procedure must be started from step 2.
ELE SYS - 80
3. Start procedure in Self-diagnosis > Keyless

remote controls programming using PADS::
3.1 With ignition key on "ON",
3.2 Access the Keyless control unit self-diagno-
sis,
3.3 Eliminate any faults stored in the "MEM" sta-
tus, and/or proceed with the resolution of any
anomaly,
3.4 Access the "Adjustments" section and start
Adjustment> Remote Control Programming fol-
lowing the guided procedure proposed by PADS,
3.5 At the end of each remote control program-
ming, PADS shows a message "Programming
successful"; with subsequent message for request
of programming a new remote control, up to a
maximum of 4 remote controls (***),
(***) The Keyless control unit gives 5 seconds
between programming one remote control and
the other.
End of remote controls programming procedure.
ELE SYS - 81
INDEX OF TOPICS
ENGINE ENG
Beverly 400 E5 Engine
This section describes the operations to be carried out on the engine and the tools to be used.
N.B.
ENG - 83
Engine Beverly 400 E5
THE UNITS OF MEASUREMENT CONTAINED IN THIS CHAPTER ARE EXPRESSED IN TERMS

OF THE DECIMAL METRIC SYSTEM. IN THE CASE OF VALUES EXPRESSED USING IMPERIAL
AND US CUSTOMARY MEASUREMENT UNITS, REFER TO THE CONVERSION TABLE IN CHAP.
«SPECIFICATIONS».
Automatic transmission
Transmission cover
- Insert the special tool.

- Rotate the engine until the driven pulley stops.
Specific tooling
- Supporting the tool, undo the fixing screw.
- Unscrew and remove the external transmission

cover's fixing screws at the crankcase.
ENG - 84
- Undo and remove the central screw from the

transmission cover.
- Remove the transmission cover.
Air duct
- Unscrew and remove the cooling cover fastening

screws.
Remove the cooling cover.
ENG - 85
Removing the driven pulley shaft bearing
- Remove the Seeger ring.

CAUTION
PLACE THE COVER ON A SURFACE, REMOVING OR EX-
CLUDING THE ALIGNMENT DOWELS.
- Using the housing to support the cover of the

transmission, interpose a few layers of heavy cloth
so as not to damage the outer surface of the cover.
- Using appropriate tools, remove the bearing.
Specific tooling
020439Y 17-mm guide
001467Y002 Driver for OD 73 mm bearing
Refitting the driven pulley shaft bearing
- Use the heat gun to heat the inner part of the lid.
CAUTION
DO NOT HEAT EXCESSIVELY SO AS NOT TO DAMAGE
THE PAINTWORK.
Specific tooling
020151Y Air heater
Using the equipment, mount a new bearing, apply

grease on the adapter and on the guide in order to
maintain the position of the bearing during opera-
tion on the vertical axis.
Specific tooling
020439Y 17-mm guide
ENG - 86
- Insert the Seeger ring.

- Insert the alignment dowels if removed during
disassembly.
Removing the driven pulley
To remove the driven pulley, proceed as follows:

- Remove the drive pulley to release the drive belt.
- Remove the driven pulley together with the belt.

WARNING
AS A RESULT OF THE OPERATION THERE MAY BE A
LIGHT "HAMMERING" BETWEEN THE KNURLING OF THE
PULLEY AXLE. THIS CAN MAKE REMOVAL BY HAND DIF-
FICULT.
IN CASE OF NEED USE AN EXTRACTOR.
Removing the clutch
- To remove the clutch assembly it is necessary to

remove the inlet pinion to the final reduction unit,
operating as described in the section «Dismount-
ing the hub cover».
ENG - 87
- Working from the automatic transmission side,

remove the driven pulley.
- Unscrew the six fixing screws from the clutch
cover.
- By using two screwdrivers work on the appendi-

ces and remove the cover taking care not to drop
the clutch assembly.
- Remove the clutch assembly.
Inspecting the clutch
COVER REVISION
- Adequately support the cover and using a screw-
driver remove the seal ring.
Specific tooling
001467Y007 Driver for OD 54-mm bearings
ENG - 88
- Working from the opposite side, supporting the

cover, proceed to the removal of the bearing.
Specific tooling
- Heat the crankcase by means of specific tools

and then insert a new bearing.
- Using the equipment plant a new bearing, apply
grease on the adapter and guide in order to main-
tain the position of the bearing during operation on
the vertical axis.
Specific tooling
020151Y Air heater
020364Y 25-mm guide
- Insert a new seal ring and grease the seal lips.
Specific tooling
- Replace the outer O-ring and grease properly.

WARNING
IN ORDER TO PREVENT ABNORMAL FORMATIONS OF

DIRT DUE TO THE RELEASE OF GREASE, WE RECOM-
MEND FIRST LUBRICATING THE SEAL RING STOPS WITH
A BRUSH.
ENG - 89
DISASSEMBLY
- Insert the clutch assembly in the special tool and
tighten the three wing nuts until you hear the end
of stroke.
- Prepare two aluminium protections in the vice
and tighten the shaft of the driven pulley.
Specific tooling
020919Y Clutch discs disassembly tool
- Using pliers remove the lock circlips.
ENG - 90
- Disengage the upper ring of the specific tool.

- Remove the outer ring with the seat for the Bel-
leville spring.
- Remove the Belleville spring.
- Remove the spring door upper disc.
- Remove the discs separation spring.

- Remove the semi-trimmed duct disc (trimmed on
one side).
- Remove a conductor disc.
- Remove the discs clearance recovery spring
- Remove a duct metallic disc.
- Remove a conductor disc (trimmed on both
sides).
ENG - 91
ENG - 92

- Remove a non-trimmed duct metallic disc.
- Remove a conductor disc (trimmed on both
sides).
- Remove the semi-trimmed duct disc (trimmed on
one side).
ENG - 93
CAUTION
THE CLEARANCE RECOVERY SPRING DISCS ARE FIT-

TED INDIVIDUALLY.
THE FIRST IN THE ASSEMBLY PHASE MUST BE POSI-
TIONED TOWARDS THE INSIDE OF THE HOUSING, AS
SHOWN IN FIGURE.
- Remove the hub.

- Remove the shaft.
ENG - 94
- Remove the lower spring holder disc complete

with the six springs.
- Remove the rollers.
- Check that there is no abnormal wear on the roll-

ers, the support channels for rollers and those for
discs.
ENG - 95
CLUTCH SPRING REVISION
Characteristic
Clutch springs
Free spring measurement 15.3 mm
Clutch spring wear limit
15,0 mm
CLEARANCE RECOVERY SPRING REVISION

Check for any deformation or abnormal wear.
Characteristic
Clearance recovery spring «A» standard di-
mensions
3.2±0.1 mm
Clearance recovery spring wear limit
2,8 mm
CLUTCH DISCS REVISION

Check the clutch discs for damage or signs of
wear: In this case, replace them all.
Measure the thickness of the discs in four posi-
tions, and if they do not meet specifications, re-
place them all.
Characteristic
Clutch discs thickness
Conductor disc thickness «B» = 3.00±0.08 mm
Trimmed duct disc thickness «C» = 1.95±0.05 mm
Duct disc thickness «D» = 1.400±0.035 mm
ENG - 96
DISCS WEAR LIMIT

If the discs exceed the following wear limits, replace them all.
Characteristic
Clutch discs wear limit
Conductor disc wear limit «B» = 2.6 mm
Trimmed duct wear limit «C» = 1.7 mm
CLUTCH DISCS REVISION: MAXIMUM DEFOR-

MATION
Measure the maximum deformation of the discs by
positioning them on a reference plane and check-
ing with a feeler gauge. If out of specification,
replace them all.
Characteristic
Clutch discs maximum deformation
Max. duct disc unevenness «D» 0.2 mm
ENG - 97
REASSEMBLY
- Working in reverse order to the removal, insert
the components while taking care to follow the fol-
lowing guidelines:
- Place the rollers as shown in the photo, after ev-
ery two leave a clearance so that each pair has its
opposite for proper balance.
- Lubricate the parts of the clutch pack with the

recommended product.
Transmission oil 80W-90 Lubricant for gear-
boxes and transmissions.
SAE 80W-90 API GL-4
CAUTION

TED INDIVIDUALLY.
THE FIRST IN THE ASSEMBLY PHASE MUST BE POSI-
SHOWN IN FIGURE.
ENG - 98
- Insert the semi-trimmed disc with the trimmed

surface facing the lower support disc
- Respect the indicated position of the discs clear-

ance recovery spring.
CAUTION

TED INDIVIDUALLY.
THE LAST IN THE ASSEMBLY PHASE MUST BE POSI-
SHOWN IN FIGURE.
- Insert the semi-trimmed disc with the trimmed

surface facing the upper support disc
- Insert the upper support disc in the spring.
ENG - 99
- Insert the Belleville spring facing upwards, taking

care to insert it properly into the seat in the closure
ring.
- Fit the specific tool to compress the clutch pack

and place the retaining ring at the specified loca-
tion.
Specific tooling
020919Y Clutch discs disassembly tool
FINAL CHECK
Once the clutch is assembled, turn by hand the exit axis to the final reduction.
The rotation must be free.
If you feel resistance in the movement, or if you detect impediments, disassemble the clutch again and
check the correct installation.
ENG - 100
CLUTCH OUTPUT SHAFT ROLLER CASING IN-

SPECTION
- Using specific tools, remove the roller casing
Specific tooling
001467Y006 Pliers to extract 20 mm bearings
- Insert a new roller casing and set it with specific

tools.
Specific tooling
020084Y punch ø 20
ENG - 101
Pin retaining collar
- Use the tool equipped with medium length pins

in "C" position screwing them from the inside of the
tool.
- Install the driven pulley into the tool providing the
support of an appendix against a pin.
- Ensure the centring of the driven pulley by means
of the key inserted on the nut.
Specific tooling
020444Y Tool for installing/removing clutch
on/from driven pulley
020444Y009 wrench 46 x 55
- Turn the key to unscrew the nut.
- Adjust the specific tool command screw to re-
lease the torque server spring.
ENG - 102
- Remove the following components in this order:
• upper cap;
• spring;
• lower spring support;
• synthetic ring.
- Using two screwdrivers lift the locking sheath of

the torque server and remove it.
ENG - 103
- Remove the two O-rings and replace them, mak-

ing sure to lubricate them during installation.
- Thoroughly clean the slots and pins.

- Check that the bushings on the pins and the slots
of the torque server are free from wear and rotate
freely.
- Then grease with recommended product using a
syringe, in order to inject the oil directly into the
holes in the bushing.
CAUTION
THE TORQUE SERVER PINS ARE SET ON THE BUSHING

WITH INTERFERENCE, AND ARE THEREFORE NOT RE-
MOVABLE. WHEN IT IS NECESSARY TO REPLACE THE
INTERNAL SEAL RINGS OR THE PULLEY SURFACES IF
THERE IS ABNORMAL WEAR, REPLACE THE DRIVEN
PULLEY UNIT.
MONTBLANC MOLYBDENUM GREASE MON-
TBLANC MOLYBDENUM GREASE
Molybdenum disulphide grease, ivory coloured;
Specification TL 9150 066, symbol NATO G 460
N.B.
GREASE USING THE CHANNELS IN THE PULLEY.
ENG - 104
- Insert the closure sheath of the torque server

taking care to respect the positioning of the ap-
pendices in their corresponding seats.
Refitting the driven pulley
- Insert the synthetic ring.
- Insert the lower spring support.
- Insert the spring, lubricating the ends.
ENG - 105
- Insert the upper cap.
- Insert the belt paying attention to the direction of

rotation.
Specific tooling
020444Y Tool for installing/removing clutch
on/from driven pulley
- Turn the control screw of the specific tool and

spring preloading.
- Insert the fixing nut and using the specific
wrench, tighten to torque.
Specific tooling
020444Y009 wrench 46 x 55
Locking torques (N*m)

Driven pulley nut 50 ÷ 60
Refitting the driven pulley
- Insert the driven pulley, complete with belt, on the

shaft.
ENG - 106
Removing the driving pulley
- Using specific tools, lock the driving pulley and

loosen the flanged nut.
Specific tooling
- remove the flat washer and the cup washer.
- remove the stationary half-pulley and the washer.
- disengage the belt.

- remove the complete roller housing.
ENG - 107
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 sliding shoes for the variator back-
plate are not worn.
- Check the wear of the roller housings and of the
belt facing 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.
CAUTION
DO NOT LUBRICATE OR CLEAN SINTERED BUSHINGS
Characteristic
movable driving half-pulley bushing: Standard
Diameter
30 mm (+0 +0.021)
movable driving half-pulley bushing: Maxi-
mum allowable diameter
Ø 26.12 mm
Sliding bushing: Standard Diameter
Ø 30 mm (-0.02 +0.041)
Sliding bushing: Minimum diameter permitted
Ø 25.95 mm
Roller: Standard diameter
Ø 25 mm±0.1
ENG - 108
Refitting the driving pulley
- perform the operations in reverse order of disas-

sembly.
CAUTION
INSERT THE ROLLERS WITH THE LARGEST SUPPORT
SURFACE ACCORDING TO THE DIRECTION OF ROTA-
TION.
- Use the specific tool to lock the pulley, tightening

to the prescribed torque.
Specific tooling

Nut M14x1.5 securing the driving pulley 120 ÷
130
CAUTION
DURING THE INSTALLATION PAY SPECIAL ATTENTION
TO THE ASSEMBLY OF THE SPRING WASHER, AS
SHOWN IN FIGURE.
Refitting the transmission cover
- Put the transmission cover.
ENG - 109
- Insert the transmission cover central screw and

tighten it to the prescribed torque.

Transmission cover screws 11 ÷ 13
- Insert and tighten the external fixing screws of the

transmission cover to the crankcase to the pre-
scribed torque.

Transmission cover screws 11 ÷ 13
- Insert the nut.

- Insert the special tool.
- Rotate the pulley axle until the pulley stops.
Specific tooling
- Supporting the tool tighten the fixing screw to the

prescribed screw.

Driven pulley M10x1.25 screw 74 ÷ 80
ENG - 110
End gear
Removing the hub cover
- Use a container large enough to recover the final

reduction oil. Unscrew the indicated screw and re-
cover the aluminium seal.
- Unscrew the oil filler screw in order to facilitate
bleeding.
- Unscrew the seven hub cap fixing screws.
ENG - 111
- Using a suitable screwdriver use leverage on the

upper and lower appendices to detach the sealant.
- Remove the final reduction cap complete with the

wheel axle, being careful not to drop the inter-
mediate gear.
- Remove the final reduction cap.

- Turn the shaft of the driven pulley until aligning a
slot with the axis of the intermediate bearing and
insert the specific tool.
Specific tooling
020918Y Clutch lock
ENG - 112
- Remove the nut and incorporated washer secur-

ing the pinion.
- The pinion is symmetrical: mark the outer surface

to avoid reversed reassembly.
- Remove the pinion and the specific tool.
CAUTION
CLEAN THE THREAD FROM ANY RESIDUAL THREAD-
LOCK.
Removing the hub bearings
REMOVAL
Removing the clutch shaft bearing
- Remove the screw and countersunk washer.
- Using the specific tools remove the bearing.
Specific tooling
020357Y 32 x 35-mm Adaptor
020363Y 20-mm guide
ENG - 113
Wheel axle bearing removal

Specific tooling
020357Y 32 x 35-mm Adaptor
020363Y 20-mm guide
Removing the intermediate gear bearing

Specific tooling
020456Y Ø 24 mm adaptor
020412Y 15-mm guide
FITTING
- Heat the crankcase by means of the specific tool and then insert the bearings.
Specific tooling
020151Y Air heater
Fitting the Wheel axle bearing

- Using the equipment set a new bearing.
Specific tooling
020363Y 20-mm guide
Fitting the Clutch shaft bearing

Specific tooling
020363Y 20-mm guide
ENG - 114
Fitting the Intermediate gear bearing

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
020412Y 15-mm guide
- After completing the insertions, tighten the lock
screw of the clutch shaft bearing, respecting the
direction of the washer and apply the recommen-
ded product.
Loctite 242 Medium strength thread-locking
sealant.
Blue

Bearing lock screw 9 ÷ 11
Refitting the ub cover
- Working in reverse order to the removal and us-

ing the specific tool, insert the control pinion, use
the recommended product and tighten the torque.
CAUTION
FOR THE INSTALLATION, ALWAYS USE NEW NUTS AL-
READY PROVIDED WITH SCOTCH GRIP.
Specific tooling
020918Y Clutch lock

M12x1.25 gear clutch shaft retainer nut 95 ÷ 105
ENG - 115
- Pay attention to the correct positioning of the

alignment dowels.
- Thoroughly clean the surfaces of the engine
crankcase and reduction cover and seal, with the
recommended product, the matching surface
around the entire outer perimeter of the duct that
leads to the breather.
CAUTION
AN IMPROPER SEALING OF THE VENTILATION CIRCUIT

MEANS A LOSS OF OIL INTO THE AUTOMATIC TRANS-
MISSION HOUSING.
THREE BOND TB1207B Liquid sealant
Three Bond liquid gasket TB1207B
- Remove the gasket.
- Insert the gears of the reduction unit in the re-

duction cover and tighten the screws to the speci-
fied torque, tightening in crossed sequence.
- Check the correct the tightening drainage screw.

Final reduction cover screws 24 ÷ 27 Reduction
unit oil drainage screw 15 ÷ 17
CAUTION
THE FOLLOWING OIL REDUCTION FILLING PROCEDURE MUST BE CARRIED OUT ONLY WITH
THE MOTOR FITTED ON THE VEHICLE, ON THE CENTRE STAND IN FLAT LAND.
- Restore the level of oil inside reduction unit with
the recommended product, acting on the filler
screw until touching.
- Tighten to the specified torque.
Transmission oil 80W-90 Lubricant for gear-
boxes and transmissions.
SAE 80W-90 API GL-4
Characteristic
Final reduction unit oil
ENG - 116
about 500 cc

Oil relief screw 15 ÷ 17
Removing the flywheel magneto
- Undo the screw indicated and remove the plate.
- Install the support plate.
Specific tooling
020916Y Magneto flywheel blocking tool
- Install the specific tool and unscrew the retainer

nut of the flywheel, recovering the washer.
Specific tooling
ENG - 117
- Act on the extractor to remove the flywheel to-

gether with the starting sprocket.
- Remove the flywheel nut with its washer
- Do up the flywheel nut by three or four threads
so that the flywheel does not fall accidentally dur-
ing extraction
- Screw the extractor onto the flywheel and extract
it as shown in the picture
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.
Specific tooling
020467Y Flywheel extractor
- Remove the tool and unscrew the nut.
- Remove the complete flywheel paying attention
to recover the tongue.
Intermediate gear
- Remove the flywheel.

- Remove the intermediate gear from its housing.
- Visually inspect the surfaces, if there is no abnormal wear, grease the housing thoroughly and insert
the intermediate gear.
ENG - 118
Refitting the intermediate gear
- Lubricate the sliding surfaces and insert the in-

termediate gear in its seat.
Refitting the flywheel magneto
- Place the tab.
- Insert the magneto flywheel on the crankshaft.
- Insert the washer.
ENG - 119
- Insert the flywheel fixing nut.
- Place the support plate.
Specific tooling
020916Y Magneto flywheel blocking tool
- Fit the specific tool.

- Tighten the flywheel fixing nut to the specified
torque.
Specific tooling

Flywheel fixing nut 100 to 110
Removing the intake manifold
- The intake manifold is housed in the big end,

loosen the clamps to remove the sleeve.
ENG - 120
- Remove the sleeve connecting the throttle body.
Removing the rocker-arms cover
- Support the big end cover.

- Unscrew and remove the special cover fastening
screws.
- Remove the big end cover.
Removing the timing system drive
- Before working on the timing system it is recom-

mended to place the engine at TDC in compres-
sion, aligning the references as shown in the
figure.
ENG - 121
- First loosen the tensioner and unscrew the fixing

screws.
- Remove the tensioner complete with gasket.
- Undo the fixing screw and remove the washer.
ENG - 122
- Remove the complete mass of the return spring.
- Loosen the screw
- Remove the counterweight fixing screw.
- Remove the counterweight.
ENG - 123
- Disengage the chain from the sprocket and re-

move the camshaft control sprocket.
Removing the cam shaft
- Remove the big end cover.

- Remove the timing system control.
- Unscrew the two screws of the camshaft lock.
- Remove the plate.
ENG - 124
- Remove the camshaft.
- Remove the lock of the rockers to allow them to

slide on the pins to access the calibrated pads.
- Remove the calibrated pads

CAUTION
PROPERLY REPLACE THE PADS AND ROCKERS SO AS
TO PRESERVE THE COUPLINGS.
CAUTION
IF NECESSARY USE A TELESCOPIC MAGNET TO RE-

MOVE THE PADS, PAY PARTICULAR ATTENTION THAT
THEY DO NOT FALL IN THE TRANSMISSION HOUSING.
- Remove the pins and the rockers.

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.
ENG - 125
Removing the cylinder head
- Undo the two external screws.
- Gradually loosen the four columns in crossed se-

quence, recovering the washers.
- Remove the cylinder head.

N.B.
IF NEEDED, THE HEAD MAY BE REMOVED WITH THE
CAMSHAFT, PINS AND ROCKING LEVERS WITHOUT RE-
MOVING THE DRIVING PULLEY UNIT. REMEMBER TO
HOLD THE TIMING CHAIN WITH A PIECE OF METAL CA-
BLE AND TO ADJUST THE CHAIN TIGHTENER UPON RE-
FITTING.
- Remove the gasket.
ENG - 126
Removing the valves
- Use the specific tool to remove the cotters, cap

and spring.
CAUTION
PROPERLY REPLACE THE PADS AND ROCKERS SO AS
TO PRESERVE THE COUPLINGS.
Specific tooling
020382Y Tool to extract valve cotters
020382Y012 bush (valve removing tool)
ENG - 127
- Use the specific tool to remove the valve oil seal.
Specific tooling
020431Y Valve oil seal extractor
- Slide off the valve and remove the lower support.
Removing the cylinder - piston assy.
- Unscrew and remove the fastening screws of the

coil.
ENG - 128
- Remove the coil.
- Unscrew and remove the lower cylinder fixing

screw.
- Remove the cylinder, paying attention to the cyl-

inder - head alignment dowels.
N.B.
IN ORDER NOT TO DAMAGE THE BASE GASKET WITH
THE PISTON LOCK FORK 020512Y DURING THE MOUNT-
ING PHASE, IT IS RECOMMENDED TO INSERT THE
ALIGNMENT DOWELS OF THE CYLINDER - CRANKCASE
UNDER THE CYLINDER DURING THE ASSEMBLY.
CAUTION
TO PREVENT DAMAGING THE PISTON, SUPPORT IT
WHILE REMOVING THE CYLINDER.
- Remove the base gasket.
ENG - 129
- Remove the retainer rings and remove the piston.

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.
Inspecting the piston

N.B.
TER.
Inspecting the piston rings

N.B.
TER.
Removing the piston
- Insert the pin.

- Insert the retainer rings.
CAUTION
POSITION THE ARROW PRINTED ON THE PISTON

CROWN TOWARDS THE EXHAUST OPENING.
CAUTION
AT EVERY NEW MOUNTING USE RETAINER RING PINS.
ENG - 130
Refitting the cylinder
- Insert the cylinder base gasket.
- Fit the specific tool.
Specific tooling
020426Y Piston fitting fork
- Place the seal rings as indicated in the figure.
- Place the cylinder and the specific tool.
Specific tooling
020128Y Piston fitting ring
ENG - 131
- Check the position of the dowels and insert the

gasket with the previously determined thickness.
Inspecting the cylinder head

N.B.
TER.
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.
Inspecting the valve sealings

N.B.
TER.
ENG - 132
Inspecting the valves
VALVE CLEARANCE CHECK

- Remove the cover.
- Position the engine to the TDC in compression.
- Using a feeler gauge check the valve clearance.

CAUTION
- USE THE FEELER GAUGE LATERALLY, IN LINE WITH
THE VALVES, IN ORDER TO PREVENT ACCIDENTAL
BENDING OF THE BLADE THAT MAY AFFECT THE MEAS-
UREMENTS.
Characteristic
Valve clearance (cold engine)
Intake: 0.10 mm Exhaust: 0.15 mm
- Detecting incorrect values, proceed with the re-

placement of the calibrated pad. To perform this
operation you must remove the rockers lock.
- Using pliers, remove the lock.
ENG - 133
- Move the rocker and replace the interested pad,

correcting the clearance in the pre-set value.
N.B.
INSERT THE CALIBRATED PADS WITH THE WORDS SIDE
VALVE IN ORDER TO PRESERVE THE INDICATION OF
THICKNESS OVER TIME.
THE OUTLET ROCKER SLIDES ON THE AXIS ONLY AF-
TER THE INTAKE ROCKER HAS BEEN MOVED. MAKE
SURE THAT THE PADS DO NOT FALL INSIDE THE ENGINE
COMPARTMENT.
Characteristic
Valve clearance (cold engine)
Intake: 0.10 mm Exhaust: 0.15 mm
- Insert the rockers lock.

- Fit the valve cover.
ENG - 134
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.
TER.
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 valve seal rings fitting
020382Y Valve cotters equipped with part 012
removal tool
020382Y012 bush (valve removing tool)
Inspecting the cam shaft

N.B.
TER.
ENG - 135
Refitting the head and timing system components

CAUTION
AT EACH REMOVAL OF THE CYLINDER HEAD IT IS NEC-
ESSARY TO REPLACE THE STUD BOLTS. FOR FITTING
QUOTA SEE THE SECTION "MOTOR/STUD BOLT SHAFT
CRANKCASE"
- Position the crankshaft to the TDC in compres-

sion.
- Insert the head gasket and check the correct op-

eration of the alignment dowels.
- Insert the chain guide slider.
- Insert the head.
- Lubricate the stud bolt threads with engine oil.
ENG - 136
- Tighten up the nuts to an initial pre-torque of 9-11

± 1 Nm.
- Tighten up the nuts by rotating 270.0±5.0° with
crossed sequence.
- 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.
CAUTION
ALWAYS USE A NEW HEAD GASKET UPON REFITTING.

Screws fixing cylinder head to crankcase 20 ÷
24 Cylinder head nut (PRE-TIGHTENING) 6 ÷ 8
Cylinder head nut (TIGHTENING) 9 ÷ 11 (Tighten
to 9 ÷ 11 Nm then proceed for 270.0° ±5.0° of rotation)
Fit the pins and rocking levers.

- Lubricate the two rockers through the upper
holes.
- Lubricate the two housings and insert the cam-
shaft in the cylinder head with the cams opposing
the rockers.
- Insert the calibrated pads and block the sliding of
the rockers by inserting the lock.
- Insert the retention plate and tighten the three
screws locking them to the specified torque. Clean
any threadlock remains from the seats, do not use
threadlock, the new screws to use during mounting
have scotch-grip application.
CAUTION
FOR THE INSTALLATION, ALWAYS USE NEW NUTS AL-
READY PROVIDED WITH SCOTCH GRIP.

Containing plate retainer screws 4.5 ÷ 5.5
ENG - 137
- Working in reverse order, assemble the camshaft

command components, respecting the phase po-
sition.
- To tighten the decompressor, bring the mass
screw to a stop and, holding it tightly, tighten the
central locking screw of the starter crown.
- Then tighten the central screw.

Pressure reducer counterweight retainer
screw 7 ÷ 8.5 Nm Timing system gear sprocket
fixing screw 11 ÷ 15
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 specified
torque.
- Insert the chain tensioning screw, together with the spring and washer, tightening it to the specified
torque.

Mount the locking chain tensioner with 2 screws 11 ÷ 13 Locking the chain tensioner support
hood 5 ÷ 6
Refitting the rocker-arms cover
- Check the status of the tappet cover gasket and

of the special screws rubber blocks.
- Fit the tappet cover paying attention to the integ-
rity of the sealing rubber blocks and to the correct
positioning of the gasket.
ENG - 138
- Tighten the special screws to the specified tor-

que.

Head cover screws 6 ÷ 7
Refitting the intake manifold
- Connect the rubber sleeve complete with throttle

body to the intake manifold.
- Place the clamps and tighten them to the speci-

fied torque.

Throttle body clamp screws 1.3 ÷ 1.7
Splitting the crankcase halves
- Undo the twelve crankcase 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.
ENG - 139
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 gasket and be careful with the align-

ment dowels.
- Remove the by-pass and the oil bulkhead.
- After removing the oil bulkhead, blow and clean

thoroughly before fitting.
Coupling chart
N.B.
TER.
ENG - 140
Refitting the crankcase halves
- Insert the crankshaft on one of the two crankcase

halves.
- insert the oil shield.
- Insert the by-pass valve.
- Place a new crankcase gasket.
ENG - 141
- Couple the crankcases, paying particular atten-

tion to avoid accidental movements during inser-
tion of the crankcase half which could cause
collision with the oil pump control toothing on the
crankshaft and, consequently, damage the bush-
ings.
- insert the crankcase fastening screws and tighten

it them to the specified torque.

Engine-crankcase coupling screws 11 ÷ 13
- Complete the coupling operations with the verifi-

cation of the crankshaft axial clearance.
- Using specific tools to support the dial gauge,
verify that the fitting clearance is within the limits.
- Higher clearances are signs of wear of the crank-
shaft - crankcase supporting surfaces.
Specific tooling
020163Y Crankcase splitting plate
020335Y Magnetic mounting for dial gauge
Characteristic
Crankshaft-crankcase axial clearance (H)
0.15 ÷ 0.43 mm
Studs
- Using two nuts, fitted as nut and lock nut type, remove and then drive from the seat.
- Proceed with a thorough cleaning of the threaded seat on the crankcase.
N.B.
THE STUD BOLTS MUST BE REPLACED AT EACH REMOVAL OF THE CYLINDER HEAD.
N.B.
NEW STUD BOLTS DO NOT NEED THREADLOCK, AS THEY COME EQUIPPED WITH SCOTCH-
GRIP.
ENG - 142
Lubrication
Conceptual diagrams
The lobe pump «F» sucks the oil from the sump, through the mesh pre-filter «C», it pushes it into the
cartridge filter «E» where there is also a safety valve «D».
Through the suitable passages found in the crankcases, the oil enters the crank chamber «G» where
the main bearings are lubricated and the big end (with high pressure), the piston pin and connecting
rod small end via spray «H».
Afterwards, the oil, through a nozzle «M» whose function is to reduce the flow rate, reaches the timing
system where it lubricates the camshaft «A» and from there, the valves and rockers. The oil passes
through the timing chain duct and returns to the sump «B» by gravity.
In the system there is a minimal oil pressure sensor «I» and a spray that serves to lubricate the stator
«L».
ENG - 143
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 bar 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 bar 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
Operating pressure
- At 1650 rpm: 0.5 - 1.2 bar
- At 6000 rpm: 3.2 - 4.2 bar

Minimum oil pressure sensor 12 ÷ 14
Crankshaft oil seals
ENG - 144
Removal
- Remove the flywheel.

- Preventing rotation, unscrew the water pump
command screw and collect the washer.
CAUTION
THE THREAD IS ANTICLOCKWISE.
- Unscrew the two screws and remove the ten-

sioner pad
- Remove the oil pump command sprocket com-

plete with chain.
- Undo the fastening screws of the oil pump.
ENG - 145
- Remove the oil pump and collect the gasket.
Inspection
- Remove the two screws and remove the oil pump

cover.
- 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.
- Using a feeler gauge, check the distance be-
tween the rotors in the position shown in the figure.
- Check the distance between the outer rotor and
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 value 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
ENG - 146
Refitting
- - Insert the oil pump with the corresponding gas-

ket in the seat.
- Insert and tighten the oil pump fastening screws

to the crankcase to the specified torque.
Loctite 243 Medium strength thread-locking
sealant.
Blue

Screws fixing oil pump to the crankcase 5 ÷ 6
ENG - 147
- Insert the oil pump driving sprocket and chain.
- fit the tensioner pad.
- place the spring washer and insert the water

pump control screw.
- Preventing rotation, tighten the water pump com-
mand screw.
CAUTION
N.B.
FIT THE BELLEVILLE WASHER SO THAT ITS OUTER RIM
TOUCHES THE PULLEY. MAKE SURE THAT THE PUMP
TURNS FREELY.

Oil pump command sprocket screw 9 ÷ 11
Removal
- Before removing the flywheel cover, loosen the

impeller.
CAUTION
CAUTION
IF THE LOCKING TORQUE IS EXCESSIVE, DO NOT INSIST
WITH THE OPERATION BUT CARRY IT OUT AFTER THE
REMOVAL OF THE FLYWHEEL COVER. AFTER REMOV-
ING THE FLYWHEEL COVER, LOCK THE IMPELLER
(DRIVE SIDE OF MOTORCYCLE) IN THE CLAMP AND,
ACTING FROM THE OPPOSITE SIDE, LOOSEN THE IM-
PELLER SHAFT (LEFT-HAND THREAD).
ENG - 148
- Keeping the cover locked in a vice, unscrew the

impeller shaft drive. During removal, support the
flywheel crankcase. Remove the drive and the
shim washer underneath.
CAUTION
- Using the special tool and appropriate supports,

ensure a proper support surface. Using a hammer
and a plug (of diameter less than 8 mm and being
careful not to damage the shaft seat) remove the
shaft and ceramic seal.
Specific tooling
001467Y002 Driver for OD 73 mm bearing
ENG - 149
- Supporting the ceramic seal properly, remove the

impeller shaft, acting from the mobile side of the
seal.
- Using a screwdriver, remove the seal ring from

the flywheel cover.
- Check that the shaft housing hole on the crank-
case does not show abnormal wear. Make sure the
ceramic seal seat does not show signs of scoring.
Check the cleaning of the drain and lubrication
holes.
ENG - 150
Fitting
- Lubricate the new seal ring with grease and insert

it in the flywheel cover.
Specific tooling
020375Y 28 x 30 mm adaptor
- Grease the shaft and insert it in the seat. Insert

the shim washer and manually start-up the drive.
ENG - 151
- Locking the drive in a vice, properly lock the shaft.

- Check that the shaft rotates freely (considering
the friction of the oil seal) and that the axial clear-
ance is noticeable but not excessive.

Water pump impeller driving joint 13 ÷ 15
- Insert the new ceramic seal using the specific

tool.
- Start the tool.
- Insert the new ceramic seal.
- Insert the housing of the tool and tighten the nut
with a wrench while holding the central pin locked.
Screw until the seal stops on the crankcase.
- The special tool provides for processing that en-
sures the proper preloading of the ceramic seal.
- Remove the tool.
Specific tooling
020661Y Water pump overall seal replacement
kit
ENG - 152
- Insert and screw the impeller to the specified tor-

que.

Impeller on the pump shaft 4 ÷ 6
ENG - 153
INDEX OF TOPICS
BRAKING SYSTEM BRAK SYS

Beverly 400 E5 Braking system
System ASR
ASR SYSTEM
The ASR system is a driving aid that assists the

driver in acceleration manoeuvres, particularly on
low-grip surfaces or under conditions that can
cause sudden back-wheel slippage. The ASR in
these situations automatically intervenes by re-
ducing engine output within the limit imposed by
the grip conditions, contributing significantly to the
maintenance of stability the vehicle.
WARNING
THE ASR SYSTEM IS BASED ON THE RECOGNITION OF

SPEED DIFFERENCES BETWEEN FRONT AND REAR
WHEEL. FOR THE SYSTEM TO PERFORM CORRECTLY IN
ALL CONDITIONS, THE PROCEDURE MUST BE PER-
FORMED EACH TIME A TYRE IS REPLACED EVEN IF ON-
LY ONE OF THE TYRES IS REPLACED.
FOR THE CALIBRATION OF THE ASR SYSTEM PERFORM
THE PROCEDURE BELOW.
WARNING
THE ASR SYSTEM PREVENTS THE APPLICATION OF

HIGH SPEED ROTATION ON THE REAR WHEEL WITH THE
VEHICLE ON THE CENTRE STAND.
IT IS RECOMMENDED TO NOT INSIST WITH THE THROT-
TLE GRIP IN THIS SPECIFIC SITUATION, BECAUSE THIS
MAY CAUSE ABNORMAL STOPS AND/OR DAMAGE TO
THE CATALYSTS.
ASR System "1" deactivation button

to deactivate the ASR system, with the engine run-
ning, press the corresponding button for at least 1
second.
ASR "2" system activation icon

System active and calibrated: icon flashes when
the key is "ON", then goes off with the engine run-
ning.
BRAK SYS - 155

Braking system Beverly 400 E5
ASR "3" system deactivation icon

Icon "ASR OFF": on steady with engine started,
ASR system not working or not calibrated or vol-
untarily deactivated.
ASR/ASR OFF ICON OPERATION MODE

ASR System status ICON with engine off ICON with engine on ASR working
or key "ON"
ACTIVE and calibrated "ASR" icon: 1Hz slow Icons switched off "ASR" icon: 5Hz fast
flashing flashing
ACTIVE not calibrated Icon "ASR OFF": on Icon "ASR OFF": on steady "ASR" icon: 5Hz fast
steady flashing
ASR voluntarily deactivated Icon "ASR OFF": on Icon "ASR OFF": on steady -
steady
ASR system not working Icon "ASR OFF": on Icon "ASR OFF": on steady -
steady
Programming phase (successful) - "ASR" icon: 1Hz slow flashing (then -
when the engine is started, the icons
turn off if the programming is suc-
cessful)
Programming phase (failed) Icon "ASR OFF": on steady when en- -
gine is started if the programming
has failed
Manual calibration procedure of the ASR sys-

tem.
In order to maintain the efficiency of the ASR sys-
tem when one or both tires are replaced, a cali-
bration procedure of the ASR system must be
performed as follows on a straight flat stretch of
road:
1. With vehicle at a standstill and engine off.
2. Pull the brake lever, turn the starter switch to
"ON" and start the engine.
3. Disconnect the ASR system by pressing the

corresponding button for at least 1 second with the
engine running; The "ASR OFF" icon will be-
come steady on, initially it was off as the ASR
system had already been calibrated in the past.
BRAK SYS - 156

Beverly 400 E5 Braking system
4. Drive at a low speed for a few meters, until the

"ABS" indicator light stops flashing.
5. To start the programming procedure, press the
start button and the ASR button at the same time
for at least 4 seconds, until the "ASR OFF" icon
starts flashing; then release the buttons.
6. Start driving and increase the speed up to 30

km/h within 1 minute, keep the speed constant
for at least 10 seconds,
The "ASR OFF" icon switched off indicates that
the calibration was successful.
7. Stop the vehicle and shut off the engine by

turning the starter switch to the "OFF" position.
8. If the procedure has been completed cor-

rectly, the next time the starter switch is turned
to the "ON" position, the "ASR" icon lights up
with 1Hz slow flashing (1 flash per second).
When starting the engine, the "ASR" icon turns off
and the ASR system will be ACTIVE.
9. If the procedure is NOT completed correctly,

the "ASR OFF" icon will be switched on steady.
By pressing the appropriate button, the user can
manually reactivate the ASR system by returning
it to the previously stored calibration.
WARNING
N.B.
BY TURNING THE STARTER SWITCH TO THE "ON" POSITION, THE FLASHING ASR ICON IN-
DICATES THE SYSTEM DIAGNOSIS PHASE. IF THERE IS NO FLASHING WHEN THE ENGINE IS
STARTED, THE ASR SYSTEM MAY NOT BE WORKING.
WARNING
BRAK SYS - 157

Braking system Beverly 400 E5
THE ASR SYSTEM IS ACTIVATED EVERY TIME, THE STARTER SWITCH IS TURNED TO THE
"ON" POSITION.
IF DISABLED BY THE USER, THE ASR SYSTEM KEEPS THE STATE OF INACTIVITY ONLY IF
THE VEHICLE IS OFF, BY USING THE ENGINE STOP SWITCH; THE NEXT TIME THE STARTER
SWITCH IS TURNED, THE ASR SYSTEM IS AUTOMATICALLY ENABLED.
CAUTION
IT IS RECOMMENDED TO PAY PARTICULAR ATTENTION IN THE EVENT OF ACCELERATION

FROM STANDSTILL IN CONDITIONS OF LOW GRIP, ESPECIALLY IN THE FIRST METRES.
CAUTION
A POOR STATE OF MAINTENANCE OF THE TYRES CAN RESULT IN ABNORMAL OPERATION

OF THE ASR SYSTEM.
IN CASE OF REPEATED INTERVENTIONS OF THE ASR, EVEN ON ROAD SURFACES WITH
GOOD GRIP OR SMALL THROTTLE OPENINGS, IT IS NECESSARY TO CHECK FOR WEAR AND/
OR THE STATE OF INFLATION OF TYRES FIRST.
CAUTION
IT IS EMPHASISED THAT THE RIDING AUXILIARY SYSTEM CANNOT CHANGE THE PHYSICAL
LIMITS OF GRIP AND IS NOT A SUBSTITUTE FOR PROPER MANAGEMENT OF POWER, BOTH
ON STRAIGHT STRETCHES AND IN TURNS. THEREFORE, IT IS RECOMMENDED TO ALWAYS
USE THE VEHICLE WITH THE UTMOST CARE AND IN ACCORDANCE WITH THE REGULATIONS
IN FORCE.
N.B.
THE DEVICE PREVENTS IMPRESSING ON THE REAR HIGH SPEED ROTATION WHEEL WITH
THE VEHICLE ON THE CENTRE STAND. IT IS RECOMMENDED NOT TO INSIST WITH THE
THROTTLE GRIP IN THIS PARTICULAR CONDITION.
N.B.
IN CASE OF ROAD DISCONNECTIONS THERE COULD BE SHORT ACTIVATIONS OF THE ASR
SYSTEM. SUCH EVENT APPEARS UNDER NORMAL OPERATION CONDITIONS OF THE VEHI-
CLE.
CAUTION
IN THE EVENT OF MALFUNCTION OF THE BATTERY, THE ABS - ASR SYSTEM TURNS OFF.
BRAK SYS - 158

B
Bulbs:
F
Fuses: 78
I
Identification: 19
Instrument panel: 68
K
Keys: 80
M
Maintenance: 18, 54
R
Recommended products: 55
S
Start-up: 11
Suspension:
T
Technical Data: 18
Transmission: 84, 109
V
Vehicle: 19

Beverly 400 E5

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Beverly 400 E5

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MANUALE STAZIONE DI SERVIZIO

GENERAL MANDATORY REQUIREMENTS

ELECTRICAL SYSTEM ELE SYS

BRAKING SYSTEM BRAK SYS

GENERAL MANDATORY REQUIREMENTS NORM

WARNINGS AND IMPORTANT NOTES

WARNINGS REACH REGULATION:

• EC Regulation 1907/2006 (REACH);

GENERAL SAFETY WARNINGS:

1. Always wear protective goggles and suitable clothing.

• Remote control and ignition switch

DIGITAL DISPLAY MEASUREMENT UNIT CON-

• With the ignition switch turned to

To set or adjust the time, with the engine running

• press and hold the SET button on the

rent value, if no changes were made) -

If the SET button is not pressed for a period ex-

FOR SAFETY REASONS THE TIME SETTING IS ONLY

DISCONNECTING THE BATTERY CABLES WILL RESULT

The ASR system is a driving aid that assists the

THE ASR SYSTEM IS BASED ON THE RECOGNITION OF

THE ASR SYSTEM PREVENTS THE APPLICATION OF

ASR System "1" deactivation button

ASR "2" system activation icon

ASR "3" system deactivation icon

ASR/ASR OFF ICON OPERATION MODE

Manual calibration procedure of the ASR sys-

3. Disconnect the ASR system by pressing the

4. Drive at a low speed for a few meters, until the

6. Start driving and increase the speed up to 30

7. Stop the vehicle and shut off the engine by

8. If the procedure has been completed cor-

9. If the procedure is NOT completed correctly,

IT IS RECOMMENDED TO PAY PARTICULAR ATTENTION IN THE EVENT OF ACCELERATION

A POOR STATE OF MAINTENANCE OF THE TYRES CAN RESULT IN ABNORMAL OPERATION

This section describes the general specifications of the vehicle.

Identification registration numbers are made up of

PLEASE REMIND THAT ALTERING IDENTIFICATION REG-

Dimensions and mass

FRONT FORK OIL

TRANSMISSIONS AND BRAKES

TRANSMISSIONS AND BRAKES

Cylinder - piston assy.

PISTON-CYLINDER COUPLING CATEGORY

- Carefully clean the seal housings.

ASSEMBLY CLEARANCE OF BANDS - SEAL RINGS

Crankcase - crankshaft - connecting rod

Axial clearance between crankshaft and connecting rod

AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD

THE CRANKSHAFT is available in two CATEGO-

CRANKSHAFT CATEGORY IDENTIFICATION:

- In case of faults, replace the head.

- Insert the valves into the cylinder head.

Measure the camshaft bearing seats and rocking

Measure the unloaded spring length

- Clean the valve seats of any carbon residues.

- Measure the diameter of the valve stems in the

MINIMUM DIAMETER PERMITTED

- Check the deviation of the valve stem by resting

- Check the oscillation of the valve head by ar-

Measure the valve guide.

- After measuring the valve guide diameter and the

- Check that there are no signs of wear on the