service station manual

service station manual
SERVICE STATION MANUAL
665018 (EN)
Beverly Tourer 125
SERVICE STATION
MANUAL
Beverly Tourer 125
The descriptions and illustrations given in this publication are not binding. While the basic specifications
as described and illustrated in this manual remain unchanged, PIAGGIO-GILERA reserves the right, at
any time and without being required to update this publication beforehand, to make any changes to
components, parts or accessories, which it considers necessary to improve the product or which are
required for manufacturing or construction reasons.
Not all versions/models shown in this publication are available in all countries. The availability of single
versions should be checked at the official Piaggio sales network.
"© Copyright 2007 - PIAGGIO & C. S.p.A. Pontedera. All rights reserved. Reproduction of this publication
in whole or in part is prohibited."
PIAGGIO & C. S.p.A. - After-Sales
V.le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi)
SERVICE STATION MANUAL
Beverly Tourer 125
This service station manual has been drawn up by Piaggio & C. Spa to be used by the workshops of
Piaggio-Gilera dealers. It is assumed that the user of this manual for maintaining and repairing Piaggio
vehicles has a basic knowledge of mechanical principles and vehicle repair technique procedures. Any
significant changes to vehicle characteristics or to specific repair operations will be communicated by
updates to this manual. Nevertheless, completely satisfactory work cannot be carried out without the
necessary equipment and tools. It is therefore advisable to read the sections of this manual relating to
appropriate tools, along with the appropriate tool catalogue.
N.B. Provides key information to make the procedure easier to understand and carry out.
CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.
WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.
Personal safety Failure to completely observe these instructions will result in serious risk of personal
injury.
Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicle
to prevent damaging the environment.
Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious
damage to the vehicle and sometimes even the invalidity of the guarantee.
INDEX OF TOPICS
CHARACTERISTICS
CHAR
TOOLING
TOOL
MAINTENANCE
MAIN
TROUBLESHOOTING
TROUBL
ELECTRICAL SYSTEM
ELE SYS
ENGINE FROM VEHICLE
ENG VE
ENGINE
ENG
SUSPENSIONS
SUSP
BRAKING SYSTEM
BRAK SYS
COOLING SYSTEM
COOL SYS
CHASSIS
PRE-DELIVERY
TIME
CHAS
PRE DE
TIME
INDEX OF TOPICS
CHARACTERISTICS
CHAR
Beverly Tourer 125
Characteristics
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 wellventilated, using special extractors if necessary; never let the engine run in an enclosed area. Exhaust
fumes are toxic.
- The battery electrolyte contains sulphuric acid. Protect your eyes, clothes and skin. Sulphuric acid is
highly corrosive; in the event of contact with your eyes or skin, rinse thoroughly with abundant water
and seek immediate medical attention.
- The battery produces hydrogen, a gas that can be highly explosive. Do not smoke and avoid sparks
or flames near the battery, especially when charging it.
- Fuel is highly flammable and it can be explosive given some conditions. Do not smoke in the working
area, and avoid naked flames or sparks.
- Clean the brake pads in a well-ventilated area, directing the jet of compressed air in such a way that
you do not breathe in the dust produced by the wear of the friction material. Even though the latter
contains no asbestos, inhaling dust is harmful.
Maintenance rules
- Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer. Non-original or
non-conforming spares may damage the vehicle.
- Use only the appropriate tools designed for this vehicle.
- Always use new gaskets, sealing rings and split pins upon refitting.
- After removal, clean the components using non-flammable or low flash-point solvents. Lubricate all
the work surfaces, except tapered couplings, before refitting these parts.
- After refitting, make sure that all the components have been installed correctly and work properly.
- For removal, overhaul and refit operations use only tools with metric measures. Metric bolts, nuts and
screws are not interchangeable with coupling members with English sizes. Using unsuitable coupling
members and tools may damage the scooter.
- When carrying out maintenance operations on the vehicle that involve the electrical system, make
sure the electric connections have been made properly, particularly the ground and battery connections.
CHAR - 7
Beverly Tourer 125
Characteristics
Vehicle identification
To read the chassis prefix, lift the saddle and remove the lid «A».
The engine prefix «B» is stamped near the rear left
shock absorber lower support.
VEHICLE IDENTIFICATION
Specification
Chassis prefix
Engine prefix
CHAR - 8
Desc./Quantity
M28801
M288M
Beverly Tourer 125
Characteristics
Dimensions and mass
VEHICLE EARTHING
Specification
Kerb weight
Maximum weight allowed
Desc./Quantity
163 kg ± 5 kg
350 kg
Engine
ENGINE
Specification
Type
Cubic capacity
Bore x stroke
Compression ratio
Engine idle speed
Timing system
Valve clearance
Max. Power
MAX. torque
Lubrication
Lubrication pressure
Minimum lubrication pressure (100° C)
Fuel supply
Cooling
Fuel
Exhaust muffler
Desc./Quantity
Single-cylinder, 4-stroke
124 cm³
57 x 48.6 mm
12 ± 0.5: 1
1650 ± 100 rpm
4 valves, single overhead camshaft, chain-driven.
Inlet: 0.10 mm Outlet: 0.15 mm
11 kW at 9,750 rpm
12 Nm at 8,000 rpm
Engine lubrication with lobe pump (inside crankcase) controlled
by a chain with double filter: mesh and paper.
4 bar
0.8 bar
KEIHIN CVEK 30 carburettor and electrical fuel pump.
Forced-circulation coolant system.
Unleaded petrol (95 RON)
absorption-type exhaust muffler with catalytic converter.
CHAR - 9
Beverly Tourer 125
Characteristics
Specification
Emission regulations
Desc./Quantity
EURO 3
Transmission
TRANSMISSION
Specification
Transmission
Desc./Quantity
Automatic expandable pulley variator with torque server, Vbelt, self-ventilating dry automatic centrifugal clutch and transmission housing with forced-circulation air cooling.
Gear reduction unit in oil bath.
Final reduction
Capacities
CAPACITY
Specification
Engine oil
Transmission oil
Cooling system fluid
Fuel tank (reserve)
Fork oil (quantity per stem)
Desc./Quantity
1.10 l
250 cm³
1.75 l
~ 10 l (2 l)
133 cm³
Electrical system
ELECTRICAL SYSTEM
Specification
Start-up
Ignition
Ignition advance
Spark plug
Alternative spark plug
Battery
Generator
Desc./Quantity
Electric
Capacitive discharge ignition, with variable advance and separate HV coil.
10° ± 1° at 2,000 rpm
CHAMPION RG4HC
NGK CR8EB
Sealed, 12 V / 10 Ah
Alternating current
Frame and suspensions
FRAME AND SUSPENSIONS
Specification
Chassis
Front suspension
Front suspension travel
Rear suspension
Rear suspension travel
Desc./Quantity
Tubular and sheet steel.
Hydraulic telescopic fork with Ø 35 mm stem
104 mm
Two double-acting shock absorbers, adjustable to four positions at preloading.
90 mm
Brakes
BRAKES
Specification
Front brake
CHAR - 10
Desc./Quantity
Ø 260-mm disc brake with hydraulic control activated by handlebar right lever.
Beverly Tourer 125
Characteristics
Specification
Rear brake
Desc./Quantity
Ø 260-mm disc brake with hydraulic control activated by handlebar left lever.
Wheels and tyres
WHEELS AND TYRES
Specification
Wheel rim type
Front rim
Rear rim
Front tyre
Rear tyre
Front tyre pressure (with passenger)
Rear tyre pressure (with passenger)
Desc./Quantity
Light alloy rims.
16 x 3.50''
16 x 3.50''
Tubeless, 110/70 - 16'' 52P
Tubeless, 140/70 - 16'' 65P
2 bar (-)
2.5 bar (-)
N.B.
CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE. REGULATE PRESSURE ACCORDING TO THE WEIGHT OF THE RIDER AND ACCESSORIES
Secondary air
The SAS for 125cc leader engines operates in a similar manner to the SAS for 2T engines.
The differences are the following:
instead of entering through the muffler as for 2T engine, the secondary air enters directly in the discharge
pipe on the head.
The 2T reed valve has a diaphragm. The unit, indicated by an arrow in the figure, has a cut-off connected
to the depression intake on the inlet manifold that cuts the air inlet in deceleration, to avoid explosions
in the muffler.
Air is drawn through the opening «A», goes through the first filter and is channelled through the opening
«B».
CHAR - 11
Characteristics
Beverly Tourer 125
Air gets to the second filter «B» through the opening shown in the figure. Now, the filtered air enters
the diaphragm device, and then is channelled to the head.
The air passes through a rigid pipe connected to the head and reaches a discharge joint in order to
supply oxygen to the unburned gases before the catalytic converter, thus favouring an improved reaction of the catalytic converter.
CHAR - 12
Beverly Tourer 125
Characteristics
Carburettor
125cc Version
Kehin
KEIHIN CARBURETTOR
Specification
Type
Model
Body stamping
Tapered pin stamping
CUT-OFF device
Diffuser
Maximum jet
Minimum jet
Max. air jet
Minimum air jet
Throttle valve spring
Minimum mixture set screw initial opening
Tapered pin
Diffuser nozzle
Starter air jet
Starter jet
Starter device resistance
Starter pin travel
Desc./Quantity
Depression carburettor
CVK 30
CVK
304D
Not present
Ø 29
105
35
70
130
100 ÷ 160 g
2
Ø 2.45
Ø 2.8
Ø 1.5
42
~ 20 Ω
10
Tightening Torques
STEERING
Name
Steering tube upper ring nut
Steering tube lower ring nut
Handlebar fixing screw
Fixing screws for handlebar control assembly U-bolts
Torque in Nm
40 ÷ 45
14 ÷ 17
45 ÷ 50
7 ÷ 10
CHAR - 13
Beverly Tourer 125
Characteristics
FRAME ASSEMBLY
Name
Engine-swinging arm bolt
Chassis-swinging arm pin nut
Spacer locking threaded bushing
Spacer locking threaded bushing lock nut
Frame arm-engine arm coupling pin nut
Bolt of the Silent block support plate
Centre stand bolt
Side stand fixing bolt
Side stand switch screw
Torque in Nm
64 - 72
64 - 72
13 ÷ 17
90 ÷ 110
33 ÷ 41
64 - 72
32 ÷ 40
40 ÷ 45
5÷7
FRONT SUSPENSION
Name
Fork locking screws cap
Hydraulic rod fixing screw
Stem support clamp tightening screws
Front wheel axle nut
Safety screw on fork leg
front mudguard to plate fixing screw
Fixing screw for mudguard plate to fork
Torque in Nm
15 ÷ 30
25 ÷ 35*
20 ÷ 25
45 ÷ 50
6÷7
4.5 ÷ 7
9 ÷ 11
* Loctite 243
REAR SUSPENSION
Name
Left lower shock absorber support bolt
Upper shock absorber clamp
Lower shock absorber clamp
Rear wheel axle nut
Fixing screw for wheel rim to hub
Muffler support arm to engine screws (*)
Torque in Nm
20 ÷ 25
33 ÷ 41
33 ÷ 41
104 ÷ 126
34 ÷ 38
20 ÷ 25
* Loctite 243
FRONT BRAKE
Name
Brake fluid pump-hose fitting
Brake fluid pipe-calliper fitting
Calliper to fork tightening screw
Brake disc screws
Oil bleed screw
Pad fastening pin
Torque in Nm
16 ÷ 20
16 ÷ 20
20 ÷ 25
8 ÷ 10
12 - 16
19.6 ÷ 24.5
REAR BRAKE
Name
Hydraulic line fixing screw
Pipe - brake calliper union
Brake disc fixing screws
Oil bleed screw
Screw tightening calliper to the support
Screw fixing rear brake calliper support to engine
Pad fastening pin
Torque in Nm
16 ÷ 20
20 ÷ 25
11 ÷ 13
12 - 16
42 ÷ 52
20 ÷ 25
19.6 ÷ 24.5
MUFFLER
Name
Screw fixing manifold to muffler
Muffler heat guard fixing screw
Exhaust fumes inlet screw
Screw fixing muffler support arm to crankcase
Nuts fixing muffler to support arm
Nut fixing muffler to cylinder head
CHAR - 14
Torque in Nm
15.5 ÷ 18.5
5-6
22 ÷ 26
33 ÷ 41
27 ÷ 30
16 ÷ 18
Beverly Tourer 125
Characteristics
LUBRICATION
Name
Hub oil drainage plug
Oil filter on crankcase fitting
Engine oil drainage plug/mesh filter
Oil filter
Oil pump cover screws
Screws fixing oil pump to crankcase
Oil pump control crown screw
Oil pump cover plate screws
Oil sump screws
Minimum oil pressure sensor
Torque in Nm
15 ÷ 17
27 ÷ 33
24 ÷ 30
4÷6
0.7 ÷ 0.9
5-6
10 ÷ 14
4÷6
10 ÷ 14
12 ÷ 14
CYLINDER HEAD
Name
Spark plug
Nuts fixing head to cylinder (1) (^)
Head fixing side screws
Starter ground screw
M5 side screw locking washers on camshaft
Tappet set screw lock nut
Timing chain tensioner slider screw
Starter ground support screw
M6 central screw locking washers on camshaft
Timing chain tensioner support screw
Timing chain tensioner central screw
Camshaft retention plate screw
Torque in Nm
12 ÷ 14
9 ÷ 11 + 180°
11 ÷ 12
7 ÷ 8.5
7 ÷ 8.5
6÷8
10 ÷ 14
11 ÷ 15
11 ÷ 15
11 ÷ 13
5-6
4÷6
TRANSMISSION
Name
Belt support roller screw
Clutch unit nut on driven pulley
Drive pulley nut
Transmission cover screws
Driven pulley shaft nut
Rear hub cover screws
Torque in Nm
11 ÷ 13
45 ÷ 50
75 ÷ 83
11 ÷ 13
54 ÷ 60
24 ÷ 27
FLYWHEEL
Name
Flywheel cover fixing screws
Stator assembly screws (°)
Flywheel nut
Pick-Up clamping screws
Screw fixing freewheel to flywheel
Torque in Nm
5-6
3÷4
52 ÷ 58
3÷4
13 ÷ 15
CRANKCASE AND CRANKSHAFT
Name
Internal engine crankcase bulkhead (transmission-side half
shaft) screws
Engine-crankcase coupling screws
Starter motor screws
Crankcase timing system cover screws (°)
Torque in Nm
4÷6
11 ÷ 13
11 ÷ 13
3.5 ÷ 4.5
COOLING
Name
Water pump rotor cover
Screws for water pump rotor driving link
Thermostat cover screws
Bleed screw:
Torque in Nm
3÷4
3÷4
3÷4
3
(°) Apply LOCTITE 242 medium-strength threadlock
CHAR - 15
Beverly Tourer 125
Characteristics
(*) The two screws must be tightened to the prescribed torque after having done so with the rear wheel
axle nut. Safety locks: see "Pre-delivery operations".
(^) Fasten the nuts in two crossed passes.
(1) Before fitting the nuts lubricate them with engine oil
Overhaul data
Assembly clearances
Cylinder - piston assy.
ENGINE COUPLING CATEGORIES
Name
Cylinder
Cylinder
Piston
Piston
Cylinder 1st Oversize
Cylinder 1st Oversize
Piston 1st Oversize
Piston 1st Oversize
Cylinder 2nd Oversize
Cylinder 2nd Oversize
Piston 2nd Oversize
Piston 2nd Oversize
Cylinder 3rd Oversize
Cylinder 3rd Oversize
Piston 3rd Oversize
Piston 3rd Oversize
CHAR - 16
Initials
A
B
C
D
A1
B1
C1
D1
A2
B2
C2
D2
A3
B3
C3
D3
Cylinder
56.997 ÷ 57.004
57.004 ÷ 57.011
57.011 ÷ 57.018
57.018 ÷ 57.025
57.197 ÷ 57.204
57.204 ÷ 57.211
57.211 ÷ 57.218
57.218 ÷ 57.225
57.397 ÷ 57.404
57.404 ÷ 57.411
57.411 ÷ 57.418
57.418 ÷ 57.425
57.597 ÷ 57.604
57.604 ÷ 57.611
57.611 ÷ 57.618
57.618 ÷ 57.625
Piston
56.945 ÷ 56.952
56.952 ÷ 56.959
56.959 ÷ 56.966
56.966 ÷ 56.973
57.145 ÷ 57.152
57.152 ÷ 57.159
57.159 ÷ 57.166
57.166 ÷ 57.173
57.345 ÷ 57.352
57.352 ÷ 57.359
57.359 ÷ 57.366
57.366 ÷ 57.373
57.545 ÷ 57.552
57.552 ÷ 57.559
57.559 ÷ 57.566
57.566 ÷ 57.573
Play on fitting
0.045 - 0.059
0.045 - 0.059
0.045 - 0.059
0.045 - 0.059
0.045 - 0.059
0.045 - 0.059
0.045 - 0.059
0.045 - 0.059
0.045 - 0.059
0.045 - 0.059
0.045 - 0.059
0.045 - 0.059
0.045 - 0.059
0.045 - 0.059
0.045 - 0.059
0.045 - 0.059
Beverly Tourer 125
Characteristics
Piston rings
ENGINE SEALING RINGS
Name
Compression ring
Oil scraper ring
Oil scraper ring
Description
Dimensions
57 x 1
57 x 1
57 x 2.5
Initials
A
A
A
Quantity
0.15 ÷ 0.30
0.10 ÷ 0.30
0.15 ÷ 0.35
Crankcase - crankshaft - connecting rod
CRANKSHAFT HALF-BEARINGS
Name
Crankshaft half-bearing
Crankshaft half-bearing
Crankshaft half-bearing
Description
Dimensions
Initials
Category B - blue
Type C - yellow
Category E - green
Quantity
1.973 ÷ 1.976
1.976 ÷ 1.979
1.979 ÷ 1.982
CRANKCASE - CRANKSHAFT COUPLINGS
Name
Crankshaft category 1 Crankcase category 1
Crankshaft category 1 Crankcase category 2
Crankshaft class 2 Crankcase class 1
Crankshaft category 2 Crankcase category 2
Description
Name
Crankshaft
Crankshaft
Crankcase
Crankcase
Description
Dimensions
Initials
E-E
Quantity
C-C
C-C
B-B
CRANKSHAFT - CRANKCASE
Dimensions
Initials
Category 1
Class 2
Category 1
Class 2
Quantity
28.998 ÷ 29.004
29.004 ÷ 29.010
32.959 ÷ 32.965
32.953 ÷ 32.959
CHAR - 17
Beverly Tourer 125
Characteristics
Fitting clearances
Crankshaft/crankcase axial clearance (H):
0.15 ÷ 0.40 mm (when cold)
AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD
Name
Half-shaft, transmission
side
Flywheel-side half-shaft
Connecting rod
Spacer tool
CHAR - 18
Description
Dimensions
16.6 +0-0.05
Initials
A
Quantity
D = 0.20 - 0.50
16.6 +0-0.05
18 -0.10 -0.15
51.4 +0.05
B
C
E
D = 0.20 - 0.50
D = 0.20 - 0.50
D = 0.20 - 0.50
Beverly Tourer 125
Characteristics
Slot packing system
Characteristic
Compression ratio
12 ± 0.5: 1
Measurement «A» to be taken, is a value of piston protrusion. It indicates by how much the plane formed
by the piston crown protrudes from the plane formed by the upper part of the cylinder. The further the
piston protrudes from the cylinder, the thicker the base gasket to be used (to restore the compression
ratio) and vice versa.
N.B.
NO GASKETS AND SEALS SHOULD BE ASSEMBLED BETWEEN THE CRANKCASE AND CYLINDER AND THE DIAL GAUGE EQUIPPED WITH SUPPORT SHOULD BE SET TO ZERO FOR
MEASUREMENT «A» TO BE TAKEN WITH THE PISTON AT TOP DEAD CENTRE POSITION AND
ON A RECTIFIED PLANE.
MODELS WITH METAL HEAD GASKET (0.3)
Name
Shimming - Cylinder 67.8 - Head gasket
0.3 - Base gasket 0.4
Shimming - Cylinder 67.8 - Head gasket
0.3 - Base gasket 0.6
Measure A
1.40 ÷ 1.65
Thickness
0.4 ± 0.05
1.65 ÷ 1.90
0.6 ± 0.05
CHAR - 19
Beverly Tourer 125
Characteristics
Oversizes
OVERSIZES
Name
Compression ring 1st
oversize
Oil scraper ring 1st
Oversize
Oil scraper ring 1st
Oversize
Compression ring 2nd
Oversize
Oil scraper ring 2nd
Oversize
Oil scraper ring 2nd
Oversize
Compression ring 3rd
Oversize
Oil scraper ring 3rd
Oversize
Oil scraper ring 3rd
Oversize
Description
Dimensions
57.2 x 1
Initials
A
Quantity
0.15 ÷ 0.30
57.2 x 1
A
0.10 ÷ 0.30
57.2 x 2.5
A
0.15 ÷ 0.35
57.4 x 1
A
0.15 ÷ 0.30
57.4 x 1
A
0.10 ÷ 0.30
57.4 x 2.5
A
0.15 ÷ 0.35
57.6 x 1
A
0.15 ÷ 0.30
57.6 x 1
A
57.6 x 2.5
A
0.15 ÷ 0.35
Products
RECOMMENDED PRODUCTS TABLE
Product
AGIP ROTRA 80W-90
Description
Rear hub oil
AGIP CITY HI TEC 4T
AGIP FILTER OIL
Oil to lubricate flexible transmissions
(throttle control)
Oil for air filter sponge
AGIP GP 330
Grease for brake levers, throttle
CHAR - 20
Specifications
SAE 80W/90 Oil that exceeds the requirements of API GL3 specifications
Oil for 4-stroke engines
Mineral oil with specific additives for increased adhesiveness
White calcium complex soap-based
spray grease with NLGI 2; ISO-L-XBCIB2
Beverly Tourer 125
Characteristics
Product
AGIP CITY HI TEC 4T
Description
Engine oil
AGIP BRAKE 4
AGIP PERMANENT SPEZIAL
Brake fluid
coolant
Specifications
SAE 5W-40, API SL, ACEA A3, JASO MA
Synthetic oil
FMVSS DOT 4 Synthetic fluid
Monoethylene glycol-based antifreeze
fluid, CUNA NC 956-16
UNIT OF MEASUREMENT - CONVERSION - ENGLISH SYSTEM AND INTERNATIONAL SYSTEM (IS).
Specification
1 Inch (in)
1 Foot (ft)
1 Mile (mi)
1 US Gallon (US gal)
1 Pound (lb)
1 Cubic inch (in³)
1 Foot pound (ft lb)
1 Miles per hour (mi/h)
1 Pound per square inch (PSI)
1 Fahrenheit (°F)
Desc./Quantity
25.4 Millimetres (mm)
0.305 Meter (m)
1.609 Kilometre (km)
3.785 Litre (l)
0.454 Kilogram (Kg)
16.4 Cubic centimetres (cm³)
1.356 Newton meter (Nm)
1.602 Kilometres per hour (km/h)
0.069 (bar)
32+(9/5) Celsius (°C)
CHAR - 21
INDEX OF TOPICS
TOOLING
TOOL
Beverly Tourer 125
Tooling
SPECIFIC TOOLS
Stores code
020151Y
Description
Air heater
020331Y
Digital multimeter
020648Y
Single battery charger
001467Y014
Pliers to extract ø 15-mm bearings
020412Y
15 mm guide
TOOL - 23
Beverly Tourer 125
Tooling
TOOL - 24
Stores code
020335Y
Description
Magnetic support for dial gauge
020565Y
Flywheel lock calliper spanner
020439Y
17 mm guide
020359Y
42x47-mm adaptor
020363Y
20 mm guide
Beverly Tourer 125
Tooling
Stores code
020459Y
Description
Punch for fitting bearing on steering tube
020458Y
Puller for lower bearing on steering tube
005095Y
Engine support
008564Y
Flywheel extractor
020434Y
Oil pressure control fitting
020382Y011
adapter for valve removal tool
TOOL - 25
Beverly Tourer 125
Tooling
TOOL - 26
Stores code
020424Y
Description
Driven pulley roller casing fitting punch
020431Y
Valve oil seal extractor
020193Y
Oil pressure gauge
020306Y
Punch for assembling valve seal rings
020360Y
Adaptor 52 x 55 mm
020364Y
25-mm guide
Beverly Tourer 125
Tooling
Stores code
020375Y
Description
Adaptor 28 x 30 mm
020376Y
Adaptor handle
020444Y
Tool for fitting/ removing the driven pulley
clutch
020330Y
Stroboscopic light to check timing
001467Y035
Belle for OD 47-mm bearings
020368Y
driving pulley lock wrench
TOOL - 27
Beverly Tourer 125
Tooling
TOOL - 28
Stores code
020319Y
Description
Immobilizer check tester
020287Y
Clamp to assemble piston on cylinder
020263Y
Sheath for driven pulley fitting
020262Y
Crankcase splitting strip
020430Y
Pin lock fitting tool
020428Y
Piston position check support
Beverly Tourer 125
Tooling
Stores code
020426Y
Description
Piston fitting fork
020425Y
Punch for flywheel-side oil seal
020423Y
driven pulley lock wrench
020414Y
28-mm guide
020393Y
Piston fitting band
020382Y
Valve cotters equipped with part 012 removal tool
TOOL - 29
Beverly Tourer 125
Tooling
TOOL - 30
Stores code
020455Y
Description
10-mm guide
020442Y
Pulley lock wrench
020440Y
Water pump service tool
020329Y
MityVac vacuum-operated pump
020357Y
020409Y
32 x 35 mm adaptor
Multimeter adaptor - Peak voltage detection
Beverly Tourer 125
Tooling
Stores code
020456Y
Description
Ø 24 mm adaptor
020332Y
Digital rev counter
020074Y
Support base for checking crankshaft
alignment
020055Y
Wrench for steering tube ring nut
002465Y
Pliers for circlips
001330Y
Tool for fitting steering seats
TOOL - 31
Beverly Tourer 125
Tooling
TOOL - 32
Stores code
020454Y
Description
Tool for fitting piston pin stops (200 - 250)
020622Y
Transmission-side oil guard punch
020444Y011
adapter ring
020444Y009
46x55 Wrench
001467Y
Extractor for bearings for holes
001467Y013
Pliers to extract ø 15-mm bearings
Beverly Tourer 125
Tooling
Stores code
020444Y010
Description
adapter ring
020244Y
15 mm diameter punch
020115Y
Ø 18 punch
020271Y
Tool for removing-fitting silent bloc
020627Y
Flywheel lock wrench
020467Y
Flywheel extractor
TOOL - 33
Beverly Tourer 125
Tooling
Stores code
020626Y
TOOL - 34
Description
Driving pulley lock wrench
INDEX OF TOPICS
MAINTENANCE
MAIN
Beverly Tourer 125
Maintenance
Maintenance chart
MAINTENANCE TABLE
●Replacement
■ Check
* Check level every 3,000 km
** Replace every 2 years
Clean the external filter of the Secondary Air System (SAS) every 2 years
km x 1,000
Driven pulley roller casing (greasing)
Safety locks
Ignition spark plug
Driving belt
Throttle control - (adjustment)
Air filter
Oil filter
Valve clearance
Electrical system and battery
Brake control lever (greasing)
Coolant level **
Brake fluid level **
Engine oil *
Hub oil
Headlight aiming adjustment
Brake pads
Sliding blocks / variable speed rollers
Tyre pressure and wear
Vehicle road test
Radiator (external cleaning)
Idle speed
Suspensions
Steering
Transmission
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Carburettor
- Disassemble the carburettor in its parts, wash all of them with solvent, dry all body grooves with
compressed air to ensure adequate cleaning.
- Check carefully that the parts are in good condition.
- The throttle valve should move freely in the chamber. Replace it in case of excessive clearance due
to wear.
- If there are wear marks in the chamber causing inadequate tightness or a free valve slide (even if it
is new), replace the carburettor.
- It is advisable to replace the gaskets at every refit
WARNING
PETROL IS HIGHLY EXPLOSIVE ALWAYS REPLACE THE GASKETS TO AVOID PETROL LEAKS
MAIN - 36
Beverly Tourer 125
Maintenance
Checking the spark advance
- To check ignition advance, use the stroboscopic
light with induction pincers connected to the spark
plug power wire.
- Connect the induction pincers being careful to
respect the proper polarity (the arrow stamped on
the pincers must be pointing at the spark plug).
- Place the light selector in central position (1 spark
= 1 crankshaft turn as in 2-T engines).
- Start the engine and check that the light works
properly and the rpm indicator can read also the
high rpm (e.g. 8000 rpm).
- If flash unsteadiness or revolution reading error
is detected (e.g. half values), increase the resistive
load on the spark plug power line (10 ÷ 15 KΩ in
series to HV wire).
- Remove the plastic cover from the slot on the flywheel cover.
- Operating on the flash corrector displacement of the bulb, make the reference on the flywheel cover
coincide with level on the water pump drive. Read the advance degrees indicated by the stroboscopic
light.
Characteristic
Ignition advance
10° ± 1° at 2,000 rpm
- Make sure the advance degrees match the rotation rpm.
- If failures are found, check the Pick-Up and the control unit power supply (positive-negative), replace
the control unit if necessary.
- The brand new control unit prevents that the engine rotation exceeds 2000 rpm.
- The programmed control unit allows the engine to rotate within the prescribed limits.
Specific tooling
020330Y Stroboscopic light to check timing
Spark advance variation
REVOLUTION LIMITER
Specification
Operation threshold
Reactivation threshold
Desc./Quantity
First threshold : 10700 ±50
Second threshold : 11000 ±50
First threshold : 10600±50
Second threshold : 10900±50
MAIN - 37
Beverly Tourer 125
Maintenance
Specification
Spark elimination
Spark plug
To service the spark plug the engine must be cold;
proceed as follows:
- Remove the spark plug inspection lid placed on
the right side of the vehicle by undoing the specified screw.
- Remove the spark plug cap.
- Remove the spark plug with the supplied wrench.
- Examine it carefully and replace it if the insulator
is chipped or cracked.
- Measure electrode gap with a thickness gauge
and, if necessary, adjust the gap by carefully bending the outer electrode forward or away.
- Make sure the sealing washer is in good conditions.
MAIN - 38
Desc./Quantity
First threshold : 1 spark on 7
Second threshold : 2 sparks on 3
Beverly Tourer 125
Maintenance
- Fit the spark plug, screw it manually and lock it
to the prescribed torque with a spark plug spanner.
- Refit the spark plug inspection lid.
CAUTION
THE SPARK PLUG MUST BE REMOVED WHEN THE ENGINE IS COLD. REPLACE THE SPARK PLUG AS INDICATED IN THE SCHEDULED MAINTENANCE TABLE. USING
NON-COMPLYING IGNITION CONTROL UNITS OR SPARK
PLUGS OTHER THAN THOSE PRESCRIBED MAY SERIOUSLY DAMAGE THE ENGINE.
Characteristic
Spark plug
CHAMPION RG4HC
Alternative spark plug
NGK CR8EB
Electrode gap
0.7-0.8 mm
Locking torques (N*m)
Spark plug 12 ÷ 14
Hub oil
Check
To check the rear hub oil level, proceed as follows:
-Park the vehicle on level ground and rest it on its
centre stand.
- Unscrew the oil dipstick «A», dry it with a clean
cloth and reinsert it, by screwing it in completely.
- Pull out the dipstick and check that the oil level is
above the indicated notch. If the oil level is below
the notch, refill the hub with the adequate amount
of oil.
- Screw the dipstick back in.
N.B.
THE REFERENCE MARKS ON THE HUB OIL LEVEL DIPSTICK, EXCEPT FOR THE ONE INDICATING THE "MAX"
LEVEL, REFER TO OTHER MODELS BY THE MANUFACTURER AND HAVE NO SPECIFIC FUNCTION FOR THIS
MODEL.
Recommended products
AGIP ROTRA 80W-90 rear oil hub
MAIN - 39
Maintenance
SAE 80W/90 Oil that exceeds the requirements of
API GL3 specifications
Characteristic
Transmission oil
250 cm³
Replacement
- Remove the oil filler plug «A».
- Unscrew the oil drainage cap "B" and drain out
all the oil.
- Screw in the drainage plug again and fill the hub
with the recommended oil.
Recommended products
AGIP ROTRA 80W-90 Rear hub oil
SAE 80W/90 Oil that exceeds the requirements of
API GL3 specifications
Characteristic
Transmission oil
150 cm³
Locking torques (N*m)
Hub oil drainage plug 15 ÷ 17
MAIN - 40
Beverly Tourer 125
Beverly Tourer 125
Maintenance
Air filter
To access the air filter:
- Undo the nine screws «A».
- Remove the air-box cover «B»
Cleaning:
- Wash the sponge with water and mild soap.
- Dry it with a clean cloth and short blasts of compressed air.
- Soak it in a mixture of 50% petrol and 50% specified oil.
- Gently squeeze the filtering element with your
hands but do not wring it; allow it to drip dry and
then refit.
CAUTION
IF THE VEHICLE IS USED ON DUSTY ROADS, IT IS NECESSARY TO SERVICE THE AIR FILTER MORE OFTEN TO
AVOID DAMAGING THE ENGINE.
Recommended products
AGIP FILTER OIL Oil for air filter sponge
Mineral oil with specific additives for increased adhesiveness
Engine oil
MAIN - 41
Maintenance
Replacement
Change oil and replace filter as indicated in the
scheduled maintenance table.
- In order to facilitate oil drainage, unscrew the cap/
dipstick «A».
- Unscrew the mesh pre-filter drainage plug «B»
on the flywheel side and let the oil drain off.
- Once all the oil has drained through the drainage
hole, unscrew and remove the oil cartridge filter
«C ».
Make sure the pre-filter and drainage plug O-rings
are in good conditions. Lubricate them and refit the
mesh filter and oil drainage plug, screwing them
up to the specified torque.
Refit the new cartridge filter being careful to lubricate the O-ring before fitting it.
Add the recommended engine oil through plug
«A». Then start up the vehicle, let it run for a few
minutes and shut it off. After five minutes check the
level and if necessary top up without exceeding the
MAX level. The cartridge filter must be replaced
every time the oil is changed.
N.B.
THE ENGINE MUST BE HOT WHEN THE OIL IS CHANGED.
Recommended products
AGIP CITY HI TEC 4T Engine oil
SAE 5W-40 Synthetic oil that exceed the requirements of API SL, ACEA A3, JASO MA specifications
Characteristic
MAIN - 42
Beverly Tourer 125
Beverly Tourer 125
Maintenance
Engine oil
1.1 l
Check
This operation must be carried out with the engine cold and following the procedure below:
- Place the vehicle on its centre stand and on flat
ground.
- Make sure the adjustment of the rear suspension
is set to the minimum preloading position.
- Unscrew the cap/dipstick «A», dry it with a clean
cloth and reinsert it, by screwing it in completely.
-Remove the cap/dipstick «A» again and check
that the level is between the MAX and MIN marks.
top-up, if required.
If the check is carried out after the vehicle has
been used, and therefore with a hot engine, the
level line will be lower; in order to carry out a correct check, wait at least 10 minutes after the engine has been stopped so as to get the correct
level.
Oil top up
The oil should be topped up after having checked the level and in any case by adding oil without exceeding the MAX level indicated on the cap/ dipstick.Restoring the level from MIN to MAX requires
approximately 400 cm³ of oil.
Engine oil filter
The cartridge filter must be replaced every time the oil is changed. Use new oil of the recommended
type for topping up and changing purposes.
Make sure the pre-filter and drainage plug O-rings are in good conditions. Lubricate them and refit the
mesh filter and oil drainage plug, screwing them up to the specified torque. Refit the new cartridge filter
being careful to lubricate the O-ring before fitting it. Change the engine oil.
Recommended products
AGIP CITY HI TEC 4T Engine oil
SAE 5W-40 Synthetic oil that exceed the requirements of API SL, ACEA A3, JASO MA specifications
MAIN - 43
Maintenance
Oil pressure warning light
The vehicle is equipped with a warning light on the
instrument panel that lights up when the key is
turned to the «ON» position. However, this light
should switch off once the engine has been started.
If the light turns on during braking, at idling
speed or while turning a corner, it is necessary
to check the oil level and the lubrication system.
Checking the ignition timing
-Remove the 4 fixing screws and move away from
the engine the flywheel cover fitted with a water
pump and cooling manifolds.
-Rotate the flywheel until the reference matches
the crankcase operation end as shown in the figure
(TDC). Make sure that the 4V reference point on
the camshaft control pulley is aligned with the reference point on the head as shown in the second
figure. If the reference mark is opposite the indicator on the head, make the crankshaft turn once
more.
-The TDC reference mark is repeated also between the flywheel cooling fan and the flywheel
cover.
To use this reference mark, remove the spark plug
and turn the engine in the opposite direction to the
normal direction using a calliper spanner applied
to the camshaft command pulley casing.
N.B.
TIME THE TIMING SYSTEM UNIT IF IT IS NOT IN PHASE.
MAIN - 44
Beverly Tourer 125
Beverly Tourer 125
Maintenance
Checking the valve clearance
-To check valve clearance, centre the reference
marks of the timing system.
- Use a thickness gauge to check that the clearance between the valve and the set screw corresponds with the indicated values. When the valve
clearance values, intake and drainage respectively, are different from the ones indicated below,
adjust them by loosening the lock nut and operate
on the register with a screwdriver as shown in the
figure.
Characteristic
Valve clearance
Inlet: 0.10 mm (when cold)
Outlet: 0.15 mm (when cold)
Cooling system
Level check
Check coolant when the engine is cold and as indicated in the scheduled maintenance tables, following the steps below.
- Set the vehicle upright on the stand and remove
the cover by undoing screw «A».
- Remove the expansion tank cover «B» by turning
it anticlockwise.
MAIN - 45
Maintenance
- Look inside the expansion tank and check that
the level is between MIN and MAX. Top up if the
coolant is below the MIN level.
If the level is not correct, proceed to top-up when
the engine is cold. If it is necessary to top up the
coolant frequently, or if the expansion tank is completely dry, you should look for the cause in the
cooling system.
WARNING
TO AVOID THE RISK OF SCALDING, DO NOT UNSCREW
THE EXPANSION TANK COVER WHILE THE ENGINE IS
STILL HOT.
WARNING
IN ORDER TO AVOID HARMFUL FLUID LEAKS WHILE RIDING, IT IS IMPORTANT TO MAKE SURE THAT THE LEVEL
DOES NOT EXCEED THE REFERENCE TONGUE TOO
MUCH.
IN ORDER TO GUARANTEE THE PROPER FUNCTION OF
THE ENGINE, IT IS NECESSARY TO KEEP THE RADIATOR
GRILLE CLEAN.
Recommended products
AGIP PERMANENT SPEZIAL coolant
Monoethylene glycol-based antifreeze fluid, CUNA NC 956-16
Braking system
Level check
The front and rear brake fluid reservoirs are both
positioned on the handlebars. 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 - 46
Beverly Tourer 125
Beverly Tourer 125
Maintenance
Top-up
Proceed as follows:
- Undo the five screws « A» and remove the windshield.
- Undo the screw «B», then remove cover «C» in
order to get access to the reservoir cap below.
- Loosen the two fixing screws «D» and remove
cover «E». Top-up the brake fluid level using only
the prescribed brake fluid and without exceeding
the maximum level.
Under normal climatic conditions, replace fluid as
indicated in the scheduled maintenance tables.
CAUTION
BRAKING CIRCUIT FLUID IS HIGHLY CORROSIVE; MAKE
SURE THAT IT DOES NOT COME INTO CONTACT WITH
THE PAINTWORK.
CAUTION
ONLY USE DOT 4-CLASSIFIED BRAKE FLUID.
WARNING
THE BRAKE FLUID IS HAZARDOUS: IN CASE OF ACCIDENTAL CONTACT, WASH OFF WITH WATER.
MAIN - 47
Maintenance
WARNING
THE BRAKING CIRCUIT LIQUID IS HYGROSCOPIC, AND
ABSORBS THE HUMIDITY OF SURROUNDING AIR. IF THE
HUMIDITY IN THE BRAKING FLUID EXCEEDS A CERTAIN
VALUE, IT WILL LEAD TO INEFFICIENT BRAKING. NEVER
USE BRAKING FLUID KEPT IN CONTAINERS THAT HAVE
ALREADY BEEN OPENED, OR PARTIALLY USED.
Recommended products
AGIP BRAKE 4 Brake fluid
FMVSS DOT 4 Synthetic fluid
Headlight adjustment
Proceed as follows:
- Position the unloaded vehicle, in running order
and with the tyres inflated to the prescribed pressure, onto a flat surface, 10 m away from a half-lit
white screen; make sure the vehicle axis is perpendicular to the screen;
- Turn on the headlight and check that the border
of the projected light beam on the screen is not
higher than 9/10 or lower than 7/10 f the height
from the ground to the centre of vehicle headlamp;
- Otherwise, adjust the headlight.
N.B.
THE ABOVE PROCEDURE COMPLIES WITH THE EUROPEAN STANDARDS REGARDING MAXIMUM AND MINIMUM HEIGHT OF LIGHT BEAMS. REFER TO THE STATUTORY REGULATIONS IN FORCE IN EVERY COUNTRY
WHERE THE vehicle IS USED.
To adjust light beams:
- Undo the five screws indicated and remove the
windshield.
MAIN - 48
Beverly Tourer 125
Beverly Tourer 125
Maintenance
- Operate on the screw indicated in order to aim
the light in the desired way.
SAS filters inspection and cleaning
- Remove the flywheel cover.
- Remove the two screws fixing the SAS valve as
shown in the figure and remove the SAS valve and
the O-ring from the support
- Remove the plastic support and the gasket as
shown in the photograph
MAIN - 49
Maintenance
- Check that the SAS valve plastic support is not
dented or distorted
- Check that the gasket is in good conditions
- Carefully clean the inside and outside filters. Replace them if damaged or abnormally distorted.
- Make sure the coupling connecting the secondary air to the head is not dented, overheated or
distorted. If there is, replace it.
- Check that the metal pipe does not have any
dents
To refit, follow the removal procedure but in reverse order, being careful to respect the direction
of the rubber coupling connecting the SAS valve
to the discharge system
CAUTION
INADEQUATE TIGHTNESS BETWEEN THE SAS VALVE
AND ITS SUPPORT INCREASES NOISE IN THE SAS SYSTEM.
CAUTION
WHEN TRAVELLING ON DUSTY ROADS, THE AIR FILTER
MUST BE CLEANED MORE OFTEN THAN SHOWN IN THE
SCHEDULED MAINTENANCE CHART.
CAUTION
NEVER RUN THE ENGINE WITHOUT THE SECONDARY
AIR FILTER
MAIN - 50
Beverly Tourer 125
INDEX OF TOPICS
TROUBLESHOOTING
TROUBL
Beverly Tourer 125
Troubleshooting
Engine
Poor performance
POOR PERFORMANCE
Possible Cause
The carburettor is dirty; fuel pump damaged
Excess of encrustations in the combustion chamber
Incorrect timing or worn timing system elements
Muffler obstructed
Air filter blocked or dirty.
Automatic starter failure
Oil level exceeds maximum
Lack of compression: parts, cylinder and valves worn
Transmission belt worn
Inefficient automatic transmission
Clutch slipping
Overheated valves
Wrong valve adjustment
Valve seat distorted
Defective floating valve
Operation
Remove, wash with solvent and dry with compressed air or replace. Check the pump control device.
Descale the cylinder, the piston, the head and the valves
Time the system again or replace the worn parts
Replace
Remove the sponge, wash with water and car shampoo, then
soak it in a mixture of 50% petrol and 50% specific oil. Press
with your hand without squeezing, allow it to drip dry and refit.
Check: mechanical movement, electric connection and fuel
supply, replace if required.
Check for causes and fill to reach the correct level
Replace the worn parts
Replace
Check the rollers, the pulley movement and make sure the
drive belt is in good conditions; replace the damaged parts and
lubricate the moveable driven pulley with specific grease.
Check the clutch system and/or the bell and replace if necessary
Remove the head and the valves, grind or replace the valves
Adjust the valve clearance properly
Replace the head assembly
Check the proper sliding of the float and the functioning of the
valve
Rear wheel spins at idle
Starting difficulties
DIFFICULT STARTING
Possible Cause
Altered fuel characteristics
Rpm too low at start-up or engine and start-up system damaged
Incorrect valve sealing or valve adjustment
- Engine flooded.
Operation
Drain off the fuel no longer up to standard; then, refill
Check the starter motor, the system and the torque limiter
Inspect the head and/or restore the correct clearance
Try starting-up with the throttle fully open. If the engine fails to
start, remove the spark plug, dry it and before refitting, make
the motor turn so as to expel the fuel excess taking care to
connect the cap to the spark plug, and this in turn to the ground.
If the fuel tank is empty, refuel and start up.
Automatic starter failure
Check: mechanical movement, electric connection and fuel
supply, replace if required.
Air filter blocked or dirty.
Remove the sponge, wash with water and car shampoo, then
soak it in a mixture of 50% petrol and 50% specific oil. Press
with your hand without squeezing, allow it to drip dry and refit.
Faulty spark plug or incorrect ignition advance
Replace the spark plug or check the ignition circuit components
The carburettor is dirty; fuel pump or vacuum valve damaged Remove, wash with solvent and dry with compressed air or replace
Battery flat
Check the charge of the battery, if there are any sulphur marks,
replace and use the new battery following the instructions
shown in the chapter
Intake coupling cracked or clamps incorrectly tightened
Replace the intake coupling and check the clamps are tightened
TROUBL - 52
Beverly Tourer 125
Troubleshooting
Possible Cause
Defective floating valve
Operation
Check the proper sliding of the float and the functioning of the
valve
Dismantle, wash with solvent and dry with compressed air
Check the pump control device
Carburettor nozzles clogged
Fuel pump fault
Excessive oil consumption/Exhaust smoke
EXCESSIVE OIL CONSUMPTION/SMOKEY EXHAUST
Possible Cause
Worn valve guides
Worn valve oil guard
Oil leaks from the couplings or from the gaskets
Worn or broken piston rings or piston rings that have not been
fitted properly
Operation
Check and replace the head unit if required
Replace the valve oil guard
Check and replace the gaskets or restore the coupling seal
Replace the piston cylinder unit or just the piston rings
Insufficient lubrication pressure
LOW LUBRICATION PRESSURE
Possible Cause
By-Pass remains open
Oil pump with excessive clearance
Oil filter too dirty
Oil level too low
Operation
Check the By-Pass and replace if required. Carefully clean the
By-Pass area.
Perform the dimensional checks on the oil pump components
Replace the cartridge filter
Restore the level adding the recommended oil type
Engine tends to cut-off at full throttle
ENGINE STOP FULL THROTTLE
Possible Cause
Faulty fuel supply
Incorrect float level
Water in the carburettor
Maximum nozzle dirty - lean mixture
Operation
Check and, if necessary, replace the pump and check the pipe
for correct sealing.
Restore the level in the tank by bending on the float the thrusting reed of the petrol inlet rod so as to have the float parallel to
the tank level with the carburettor inverted.
Empty the tank through the appropriate bleed nipple.
Wash the nozzle with solvent and dry with compressed air
Engine tends to cut-off at idle
ENGINE STOP IDLING
Possible Cause
Incorrect timing
Cut off device failure
Incorrect idle adjustment
Pressure too low at the end of compression
Faulty spark plug or incorrect ignition advance
The starter remains on
Minimum nozzle dirty
Operation
Time the system and check the timing system components
Check that the following parts work properly: valve; diaphragm;
spring; and that the air calibration elements are clean; check if
the sponge filter is clean too
Adjust using the rpm indicator
Check the thermal group seals and replace worn components
Replace the spark plug or check the ignition circuit components
Check: electric wiring, circuit not interrupted, mechanical
movement and power supply; replace if necessary
Wash the nozzle with solvent and dry with compressed air
TROUBL - 53
Beverly Tourer 125
Troubleshooting
Excessive exhaust noise
EXCESSIVE EXHAUST NOISE
Possible Cause
Secondary air device cut-off valve not working
Depression intake pipe of the secondary air device disconnected or dented
Reed valve of the secondary air device does not close correctly
and wears out the rubber coupling between the device and the
head pipe
Operation
Replace the secondary air device
Replace the pipe
Replace the device and the coupling
High fuel consumption
HIGH FUEL CONSUMPTION
Possible Cause
Float level
Loose nozzles
Starter inefficient
Air filter blocked or dirty.
Operation
Restore the level in the tank by bending on the float the thrusting reed of the petrol inlet rod so as to have the float parallel to
the tank level with the carburettor inverted.
Check the maximum and minimum nozzles are adequately
fixed in their fittings
Check: electric wiring, circuit continuity, mechanical sliding and
power supply
Remove the sponge, wash with water and car shampoo, then
soak it in a mixture of 50% petrol and 50% specific oil. Press
with your hand without squeezing, allow it to drip dry and refit.
SAS malfunctions
ANOMALIES IN THE SECONDARY AIR DEVICE
Possible Cause
Secondary air device cut-off valve not working
Depression intake pipe of the secondary air device disconnected or dented
Reed valve of the secondary air device does not close correctly
and wears out the rubber coupling between the device and the
head pipe
Operation
Replace the secondary air device
Replace the pipe
Replace the device and the coupling
Transmission and brakes
Clutch grabbing or performing inadequately
IRREGULAR CLUTCH PERFORMANCE OR SLIPPAGE
Possible Cause
Faulty clutch
TROUBL - 54
Operation
Check that there is no grease on the masses. Check that the
clutch mass contact surface with the casing is mainly in the
centre with equivalent characteristics on the three masses.
Check that the clutch casing is not scored or worn in an anomalous way
Beverly Tourer 125
Troubleshooting
Insufficient braking
INSUFFICIENT BRAKING
Possible Cause
Inefficient braking system
Fluid leakage in hydraulic braking system
Operation
Check the pad wear (1.5 min). Check that the brake discs are
not worn, scored or warped. Check the correct level of fluid in
the pumps and change brake fluid if necessary. Check there is
no air in the circuits; if necessary, bleed the air. Check that the
front brake calliper moves in axis with the disc.
Failing elastic fittings, plunger or brake pump seals, replace
Brakes overheating
BRAKES OVERHEATING
Possible Cause
Rubber gaskets swollen or stuck
Compensation holes on the pump clogged
Brake disc slack or distorted
Defective piston sliding
Operation
Replace the components.
Clean carefully and blast with compressed air
Check the brake disc screws are locked; use a dial gauge and
a wheel mounted on the vehicle to measure the axial shift of
the disc.
Check calliper and replace any damaged part.
Electrical system
Battery
BATTERY
Possible Cause
Battery
Operation
This is the device in the system that requires the most frequent
attention and the most thorough maintenance. If the vehicle is
not used for some time (1 month or more) the battery needs to
be recharged periodically. The battery runs down completely in
the course of 3 months. If the battery is fitted on a motorcycle,
be careful not to invert the connections, keeping in mind that
the black ground wire is connected to the negative terminal
while the red wire is connected to the terminal marked+.
Steering and suspensions
Rear wheel
REAR WHEEL ROTATES WITH ENGINE AT IDLE
Possible Cause
Idling rpm too high
Clutch fault
Operation
Adjust the engine idle speed.
Check the springs / clutch masses
TROUBL - 55
Beverly Tourer 125
Troubleshooting
Controls
STEERING CONTROLS AND SUSPENSIONS
Possible Cause
Torque not conforming
Steering hardening
Malfunctions in the suspension system
Seal fault or breakage
TROUBL - 56
Operation
Check the tightening of the top and bottom ring nuts. If irregularities continue in turning the steering even after making the
above adjustments, check the rotation seats and the steering
fifth wheels.
Check the tightening of the top and bottom ring nuts. If irregularities continue in turning the steering even after making the
above adjustments, check the rotation seats and the steering
fifth wheels.
If the front suspension is noisy, check: locking torques, headstock components, inspect forks.
Replace the shock absorber
INDEX OF TOPICS
ELECTRICAL SYSTEM
ELE SYS
Electrical system
Components arrangement
ELE SYS - 58
Beverly Tourer 125
Beverly Tourer 125
Electrical system
1. Voltage regulator: remove the right side fairing
to reach it.
Electric characteristic
Control voltage
14÷15 V to 1500÷12000 rpm
2. Start-up remote control switch: remove the right
side fairing to reach it.
3. Primary fuses: remove the right side cover to
reach them.
4. Fuel electric pump control device: remove the
right side fairing to reach it.
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Electrical system
5. Stator: remove the right side fairing to reach the
connector.
6. HV coil: remove the right side fairing to reach it.
Electric characteristic
HV coil resistance primary value:
~ 0.5 Ω
HV coil resistance secondary value:
~ 2.88 KΩ
7. Spark plug: remove the cover on the vehicle
right side to reach it.
8. Fuel electric pump: remove the right footrest to
reach it.
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Electrical system
9. Horn: remove the right footrest to reach it.
10. Electric fan: remove the shield back plate to
reach it.
11. Electronic ignition device: remove the front
shield to reach it.
12. Immobilizer aerial: remove the shield back
plate to reach it.
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Electrical system
13. Key switch: remove the front shield to reach it.
14. Remote control switches: remove the front
shield to reach them.
A. Light remote control
B. Engine stop remote control
C. Immobilizer remote control
15. Thermoswitch: remove the shield back plate to
reach it.
16. Auxiliary fuses: located in the front glove-box.
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Electrical system
17. Fuel level transmitter: remove the central cover
to reach it.
Electric characteristic
Resistance value when the tank is full
<= 7 Ω
Resistance value when the tank is empty
90 +13/-3 Ω
18. Stand switch: remove the left footrest to reach
it.
19. Automatic starter: to reach the connector, remove the inspection cover in the helmet compartment and release it from its retainer.
20. Saddle opening actuator: remove the left side
panel to reach it.
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Electrical system
21. Battery: remove the battery cover located in
the helmet compartment to reach it.
Characteristic
Battery
12V-12Ah
22. Plug socket: located in the helmet compartment.
23. Thermistor: remove the inspection cover located in the helmet compartment to reach it.
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Beverly Tourer 125
Beverly Tourer 125
Electrical system
Instrument panel
A = Immobilizer LED
B = Speedometer (mph)
C = Total Odometer
D = Speedometer (km/h)
E = High-beam warning light
F = Oil pressure warning light
G = Digital clock
H = Low fuel warning light
I = Right turn indicator warning light
L= Clock controls
M = Fuel gauge
N= Water temperature gauge
O = Headlight warning light
P = Trip odometer
Q = Odometer reset button
R = Left turn indicator warning light
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Electrical system
Ground points
A. Ground points on the chassis: remove the left
footrest to reach them.
B. Ground point on the engine: remove the left
footrest to reach it.
Checks and inspections
Immobiliser
The electric ignition system is fed with direct current and is protected by an antitheft immobilizer
integrated to the control unit.
The ignition system consists of:
- electronic control unit
- immobilizer aerial
- master and service keys with built-in transponder
- H.V. coil
- diagnosis LED
The diagnosis LED also works as a blinking light
to deter theft. This function is activated every time
the key switch is set to «OFF», when the side
stand is lowered or the engine emergency cut-off
switch is set to «OFF». It remains activated for 48
hours in order not to affect the battery charge.
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Beverly Tourer 125
Electrical system
When the ignition switch is turned to «ON», the
deterring blinker function is deactivated. Subsequently, a flash confirms the switching to « ON».
The duration of the flash depends on the electronic
control unit program (see figure).
In case the LED turns off and remains so even
when switching over to «ON», check if:
- the battery is charged
- the 4A fuse (No. 5) is in working order.
If the deterring LED remains off, check the control
unit power supply as follows:
- Disconnect the control unit connector and check
if:
- There is battery voltage between terminal No. 4
(Red/Black) and the ground lead
- There is battery voltage between the terminal No.
4 (Red/Black) and the terminal No. 8 (Black) as
shown in the figure.
- There is battery voltage between the terminals
No. 5 and No. 8 with the key switch set to «ON»,
the side stand folded up and the emergency cutoff switch set to «RUN».
If no faults are found, replace the control unit; otherwise, check the wiring and the following components:
- Engine stop remote control;
- Emergency cut-off switch;
- Side stand contacts;
- Key switch contacts.
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Electrical system
Virgin circuit
If the ignition system has not been programmed,
the engine can be started but it will run limited to
2000 rpm. When trying to accelerate, some evident loss of power may be felt.
The MASTER and SERVICE keys must be used
to code the system as follows:
- Insert the MASTER key, turn it to «ON» and keep
it in that position for 2 seconds (limit values: 1 ÷ 3
seconds).
- Alternately insert all the available black keys, setting each of them to «ON» for 2 seconds.
- Insert the MASTER key again and turn it to «ON»
for 2 seconds.
The maximum time to change keys is 10 seconds.
A maximum of 7 service keys can be programmed
at one time.
Sequence and times must be strictly observed or
it will be necessary to repeat the procedure from
the start.
Once the control unit has been programmed, the
control unit is inseparably matched with the MASTER key transponder.
This matching allows programming further service
keys in case of loss, replacement, etc. Each new
time new data is programmed the previously stored one is deleted.
If a service key setting is lost, it is essential to
carefully check the efficiency of the high voltage
system:
Shielded cap resistance ~ 5000 Ω.
In any case it is advisable to use resistive spark
plugs.
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Electrical system
Diagnostic codes
The Immobilizer system is tested each time the
key switch is turned from «OFF» to «ON». During
this diagnosis phase a number of control unit statuses can be identified and various light codes
displayed. Regardless of the code transmitted, if
at the end of the diagnosis the led remains off permanently, the ignition is enabled. If, however, the
led remains on permanently, it means the ignition
is inhibited:
1. Previously unused control unit - key inserted: a single 2 second flash is displayed, after
which the LED remains off permanently. The keys
can be stored to memory, the vehicle can be started but with a limitation imposed on the number of
revs.
2. Previously unused control unit - transponder absent or cannot be used: The LED is permanently ON; in this condition, no operations are
possible, including starting of the vehicle.
3. Programmed control unit - the service key in
(normal condition of use): a single 0.7-second
flash is displayed, after which the LED remains off
steadily. The engine can be started.
4. Programmed control unit - Master key in: a
0.7 sec. flash is displayed followed by the LED remaining off for 2 sec. and then by short 0.46 sec.
flashes the same number of times as there are
keys stored in the memory including the Master
key. When the diagnosis has been completed, the
LED remains permanently OFF. The engine can
be started.
5. Programmed control unit - fault detected: a light code is displayed according to the fault detected,
after which the LED remains on permanently. The engine cannot be started. The codes that can be
transmitted are:
- 1-flash code
- 2-flash code
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Beverly Tourer 125
- 3-flash code
Diagnostic code - 1 flash
The one-flash code indicates a system where the
serial line is not present or is not detected. Check
the Immobilizer aerial wiring and change it if necessary.
Diagnostic code - 2 flashes
A two-flash code shows a system where the control unit does not show the transponder signal. This
might depend on the inefficiency of the immobiliser
aerial or the transponder.
Turn the switch to «ON» using several keys: if the
code is repeated even with the Master key, check
the aerial wiring and change it if necessary. If this
is not the case, replace the defective key and/or
reprogram the control unit.
Diagnostic code - 3 flashes
A three-flash code indicates a system where the
control unit does not recognise the key. Turn the
switch to «ON» using several keys: if the error
code is repeated even with the Master key, replace
the control unit. If this is not the case, perform a
reprogramming.
Ignition circuit
Once the immobilizer system is enabled, the HV coil and the signals from the Pick-Up will produce a
spark in the spark plug.
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Electrical system
The battery provides the basic power supply. The system is adjusted so that the start-up system immediately detects an eventual battery voltage drop, but this is practically irrelevant for the ignition
system.
The Pick-Up is connected to the control unit by a single cable; then, for the ground circuit, the control
unit is connected to the Pick-Up by the chassis and the engine ground lead.
To avoid disturbances in the ignition system during start-up, it is very important that the engine-chassis
ground connection bonding is efficient.
No spark plug
WARNING
ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS
DISCONNECTED.
Once the lack of power to the spark plug has been
detected and the LED indicates it can be ignited,
follow this procedure:
Pick-Up check
Disconnect the control unit connector and check
the resistance value between terminal No. 2
(Green) and terminal No. 8 (Black). Check the
Pick-Up and its power line:
Electric characteristic
Pick-up resistance value
Pick-up resistance value: 105 ÷ 124 Ohm
If a break in the circuit is found, check again the flywheel and the engine ground connectors (see engine
manual). If non-conforming values are measured, replace the Pick-Up; otherwise, repair the cable harness.
In case conforming values are measured, try replacing the control unit (without programming) and make
sure the failure has been solved by checking sparks are produced in the spark plug; only then program
the control unit.
HV coil primary check
Disconnect the control unit connector and check
that the cable between terminal No. 3 and terminal
No. 8 is not interrupted (see figure).
If non-conforming values are measured, check
again the HV primary coil directly on the positive
and negative terminals. If non-conforming values
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Electrical system
are measured, repair the cable harness or else replace the HV coil.
Electric characteristic
HV coil resistance primary value:
~ 0.5 Ω
HV coil secondary check
Disconnect the spark plug cap from the HV cable
and measure the resistance between the HV cable
end and the HV coil negative terminal (see figure).
If non-conforming values are measured, replace
the HV coil. To carry out a more complete diagnosis, check the peak voltage with the multimeter
adaptor.
Electric characteristic
HV coil resistance secondary value:
~ 2.88 KΩ
Pick-Up
- Disconnect the control unit connector and connect the positive wire to connector No. 2 and the
negative wire to connector No. 8 (see figure).
- The multimeter end of a scale should be 200V.
Use the start-up system to run the engine and
measure the voltage produced by the Pick-Up.
- Replace the Pick-Up if non-conforming values
are measured.
N.B.
THE MULTIMETER MUST BE SELECTED TO DETECT
CONTINUOUS VOLTAGE.
Specific tooling
020409Y Multimeter adaptor - Peak voltage detection
Electric characteristic
Voltage value
> 5 Volt
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Electrical system
H.V. coil
With the control unit and HV coil connected, measure the voltage of the coil primary during the startup test with the voltage peak adaptor and connecting the positive terminal to the ground one and
the negative to the coil positive connector.
If non-conforming values are measured, replace
the control unit.
N.B.
THE PLASTIC CAP OF THE POSITIVE TERMINAL ON THE
HV COIL PRIMARY IS BLACK AND THE NEGATIVE TERMINAL ONE IS GREEN.
Electric characteristic
High voltage coil voltage value
High voltage coil voltage value: > 100 Volt
Battery recharge circuit
The recharge system is provided with a three phase alternator with permanent flywheel.
The alternator is directly connected to the voltage regulator.
In turn, the latter is directly connected to earth and to the battery positive passing through the 15A safety
fuse.
This system therefore requires no connection to the key switch.
The three- phase generator provides good recharge power and at low revs, a good compromise is
achieved between generated power and idle stability.
For this reason, it is very important that the idle speed is adjusted as prescribed.
Stator check
Disconnect the connector from the voltage regulator and check there is continuity between any
yellow cable and the other two cables.
Electric characteristic
Resistance value
~ 0.6 Ω
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Electrical system
Also check that all yellow cables are insulated from
the ground connection.
If non-conforming values are detected, repeat the
checks directly to the stator. In case of further repetitions of incorrect values replace the stator or
repair the wiring.
Voltage regulator check
With a perfectly charged battery and lights off,
measure voltage at the battery poles with a high
running engine.
Voltage should not exceed 15 Volt.
In case higher voltages are detected, replace the
regulator.
In case of voltage values lower than 14 Volt, check
the stator and the corresponding cable harness.
Electric characteristic
Control voltage
14÷15 V to 1500÷12000 rpm
Recharge system voltage check
Connect an ammeter induction clamp to the voltage regulator positive terminal, measure the battery voltage and turning on the vehicles lights with
engine off, wait for the voltage to set at about 12
V. Start the engine and measure the current generated by the system with lights on and a high
running engine.
In case the generated current value is lower than
10A, repeat the test using a new regulator and/
stator alternatively.
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Electrical system
Starter motor
KEY
1. Battery
2. Fuse No. 7
3. Start-up remote control
4. Starter motor
5. Key switch contacts
6. Immobiliser remote control
7. Engine stop remote control
8. Fuse No. 2
9. Stop button
10. Stop light bulb
11. Engine stop switch
12. Stand switch
13. Starter button
WARNING
ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS
DISCONNECTED.
If it does not work:
1) Check that the Red cable between the battery and the start-up remote control switch, and the latter
and the starter motor are not interrupted.
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Electrical system
Beverly Tourer 125
2) Check the start-up remote control switch, the immobilizer remote control and the engine stop remote
control.
3) Check the contacts of the key switch, the starter button, the stop buttons, the stand switch and the
engine stop switch.
4) Check that fuse No. 2 and 7 operate properly.
5) If none of these components is damaged, check wiring for continuity.
Horn control
KEY
1. Battery
2. Fuse No. 7
3. Key switch contacts
4. Fuse No. 3
5. Horn button
6. Horn
WARNING
ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS
DISCONNECTED.
If the horn does not work:
1) Check that fuse No. 3 and 7 operate properly.
2) Check the key switch and horn button contacts.
3) If the components are not damaged, check wiring for continuity.
Choke Inspection
Refer to the engine section to check the resistance and operating conditions of the component. As
regards voltage supply, keep the connector connected to the system and check that the two terminals
receive battery voltage with the engine on (see figure).
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Electrical system
If no voltage is detected, connect the multimeter
negative lead to the ground connection and the
positive lead to the automatic starter White-Black
cable; with the key switch set to «ON» check
whether there is battery voltage; if there is no voltage, check the wiring connections to the key
switch and that the 15A fuse (No. 7) works properly.
If there is voltage, check again the ignition control
unit connector.
After disconnecting the starter, start up the engine
and keep it at idle speed; then check whether there
is voltage connecting the multimeter positive lead
to terminal No. 5 (Green-Red), and the negative
one to terminal No. 7 (White-Black) (see figure).
If there is no voltage, replace the control unit after
making sure that the fuses are not blown; otherwise, check the cable harness between the starter
and the control unit and, as a last resource, replace the starter.
Turn signals system check
KEY
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Electrical system
Beverly Tourer 125
1. Battery
2. Fuse No. 7
3. Key switch contacts
4. Stand switch
5. Engine stop switch
6. Engine stop remote control
7. Right turn indicator bulbs
8. Left turn indicator bulbs
9. Turn indicator switch
10. Electronic ignition device
WARNING
ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS
DISCONNECTED.
If turn indicators do not work:
1) Check that bulbs operate properly.
2) Disconnect the control unit connector and check
if there is voltage between:
- terminal No. 4 and ground lead.
- terminal No. 4 and No. 8
- terminal No. 5 and No. 8 with the key switch set
to «ON», side stand up and engine stop switch set
to «RUN».
3) If no voltage is detected, check the fuse No. 7,
the engine stop remote control, the key switch
contacts, engine stop switch and stand switch.
4) If the components are not damaged, check wiring for continuity.
5) Jump terminals No. 1 and No. 4 and turn the
turn indicator switch alternately to the left and to
the right and check if the lights turn on.
6) If they do not turn on, check the turn indicator
switch contacts and wiring continuity.
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Electrical system
level indicators
WARNING
ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS
DISCONNECTED.
If faults are detected:
1) With a multimeter, check resistance values between the White-Green cable and the Black cable
of the fuel level transmitter by moving the arm with
the float.
2) If the transmitter operates correctly but the indication on the instrument panel is not exact,
check that the cable harnesses between them are
not interrupted.
Electric characteristic
Resistance value when the tank is full
<= 7 Ω
Resistance value when the tank is empty
90 +13/-3 Ω
Lights list
LIST OF BULBS
1
Specification
High-/low-beam bulb
2
Front tail light bulb
3
Front turn indicator bulbs
4
Rear turn indicator bulbs
5
Rear tail light bulb
6
Stop light bulb
7
Instrument panel light bulbs
8
Helmet compartment light bulb
9
License plate light bulb
Desc./Quantity
Type: Halogen (H4)
Quantity: 1
Power: 12V - 55/60W
Type: Incandescent (W 2.1 x 9.5 d)
Quantity: 1
Power: 12V - 5W
Type: Incandescent (BAU 15 S)
Quantity: 2
Power: 12V - 10W
Type: Incandescent (BAU 15 S)
Quantity: 2
Power: 12V - 10W
Type: Incandescent (W 2.1 x 9.5 d)
Quantity: 1
Power: 12V - 3W
Type: Incandescent (BAU 15 S)
Quantity: 1
Power: 12V - 10W
Type: Incandescent (W2 x 4.6 d)
Quantity: 1
Power: 12V - 1.2W
Type: Incandescent (SV 8.5)
Quantity: 1
Power: 12V - 5W
Type: Incandescent (W2.1 x 9.5 d)
Quantity: 1
Power: 12V - 5W
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Electrical system
Fuses
The electrical system is equipped with:
1. Four protection fuses «A» plus two fuses not
used located inside the right side fairing;
2. Four protection fuses «B» located inside the
glove-box on the left upper part of the compartment.
The chart shows the position and characteristics
of the fuses in the vehicle.
CAUTION
BEFORE REPLACING A BLOWN FUSE, FIND AND SOLVE
THE FAILURE THAT CAUSED IT TO BLOW. NEVER TRY
TO REPLACE THE FUSE WITH ANY OTHER MATERIAL
(E.G., A PIECE OF ELECTRIC WIRE).
CAUTION
MODIFICATIONS OR REPAIRS TO THE ELECTRICAL SYSTEM, PERFORMED INCORRECTLY OR WITHOUT STRICT
ATTENTION TO THE TECHNICAL SPECIFICATIONS OF
THE SYSTEM, CAN CAUSE ERRORS IN FUNCTIONING
AND RISK OF FIRE.
FUSES
1
Specification
Fuse No. 1
2
Fuse No. 2
ELE SYS - 80
Desc./Quantity
Capacity: 3A
Protected circuits:Fuel electric pump control device.
Fuse No. 2
Capacity: 7.5 A
Beverly Tourer 125
Electrical system
Specification
3
Fuse No. 3
4
Fuse No. 4
5
Fuse No. 5
6
Fuse No. 6
7
Fuse No. 7
8
Fuse No. 8
Desc./Quantity
Protected circuits: Stop light, start-up circuit
Fuse No. 3
Capacity: 7.5 A
Protected circuits: Horn, high-beam light - "Passing"
mode, instrument panel
Fuse No. 4
Capacity: 7.5 A
Protected circuits:Tail lights, license plate light, instrument panel lighting
Fuse No. 5
Capacity: 4A
Protected circuits: Immobilizer clock
Fuse No. 6
Capacity: 10 A
Protected circuits: High-beam light, low-beam light,
fuse No. 4
Fuse No. 7
Capacity: 15A
Protected circuits: Battery recharge circuit, electric fan,
electronic ignition device
Live:Fuses 1-2-3, light remote control, starter, engine
stop relay, immobilizer relay, start-up, electronic ignition
device.
Fuse No. 8
Capacity: 15A
Protected circuits: Plug socket, helmet compartment
light.
Sealed battery
If the vehicle is provided with a sealed battery, the only maintenance required is the check of its charge
and recharging, if necessary.
These operations should be carried out before delivering the vehicle, and on a six-month basis while
the vehicle is stored in open circuit.
Besides, upon pre-delivery it is therefore necessary to check the battery charge and recharge it, if
required, before storing the vehicle and, afterwards, every six months.
INSTRUCTIONS FOR THE BATTERY REFRESH AFTER OPEN-CIRCUIT STORAGE
1) Voltage check
Before installing the battery on the vehicle, check the open circuit voltage with a regular tester.
- If voltage exceeds 12.60 V, the battery can be installed without any renewal recharge.
- If voltage is below 12.60 V, a renewal recharge is required as explained in 2).
2) Constant voltage battery charge mode
- Constant voltage charge equal to 14.40 ÷ 14.70V
- Initial charge voltage equal to 0.3 ÷ 0.5 for Nominal capacity
- Charge time:
10 to 12 h recommended
Minimum 6 h
Maximum 24 h
3) Constant current battery charge mode
- Charge current equal to 1/10 of the nominal capacity of the battery
- Charge time: 5 h
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Beverly Tourer 125
CAUTION
NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY. USING
A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE
A FIRE.
CHARGE THE BATTERY BEFORE USE TO ENSURE OPTIMUM PERFORMANCE. INADEQUATE
CHARGING OF THE BATTERY WITH A LOW ELECTROLYTE LEVEL BEFORE IT IS FIRST USED
SHORTENS THE LIFE OF THE BATTERY.
IF THE VEHICLE IS NOT USED FOR SOME TIME (1 MONTH OR MORE) THE BATTERY NEEDS
TO BE RECHARGED PERIODICALLY. THE BATTERY RUNS DOWN COMPLETELY IN THE
COURSE OF THREE MONTHS. IF IT IS NECESSARY TO REFIT THE BATTERY IN THE VEHICLE,
BE CAREFUL NOT TO REVERSE THE CONNECTIONS TAKING INTO ACCOUNT THAT THE
GROUND WIRE (BLACK) MARKED(-) MUST BE CONNECTED TO THE - NEGATIVE TERMINAL
WHILE THE OTHER TWO RED WIRES MARKED (+) MUST BE CONNECTED TO THE TERMINAL
MARKED WITH THE +POSITIVE SIGN
WARNING
WHEN THE BATTERY IS REALLY FLAT (WELL BELOW 12.6V) IT MIGHT OCCUR THAT 5 HOURS
OF RECHARGING ARE NOT ENOUGH TO ACHIEVE OPTIMAL PERFORMANCE.
GIVEN THESE CONDITIONS IT IS HOWEVER ESSENTIAL NOT TO EXCEED 8 HOURS OF CONTINUOUS RECHARGING SO AS NOT TO DAMAGE THE BATTERY ITSELF.
The battery should always be kept clean, especially on its top side, and the terminals should be coated
with Vaseline.
Normal bench charging must be performed using the specific battery charger, setting the selector to
the type of battery that requires recharging (i.e., at a current equal to 1/10 of the battery rated capacity).
Connections to the power supply source must be implemented by connecting corresponding poles (+
to + and - to - ).
Dry-charge battery
WARNING
THE BATTERY ELECTROLYTE IS POISONOUS AS IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SULPHURIC ACID. AVOID CONTACT WITH THE EYES, THE SKIN AND CLOTHING. IF
COMING INTO CONTACT WITH EYES OR SKIN, WASH ABUNDANTLY WITH WATER FOR APPROX. 15 MIN. AND SEEK IMMEDIATE MEDICAL ATTENTION.
IN THE EVENT OF ACCIDENTAL INGESTION OF THE LIQUID, IMMEDIATELY DRINK LARGE
QUANTITIES OF WATER OR MILK, MAGNESIUM MILK, BATTERED EGG OR VEGETABLE OIL.
SEEK IMMEDIATE MEDICAL ATTENTION.
THE BATTERIES PRODUCE EXPLOSIVE GAS; KEEP CLEAR OF NAKED FLAMES, SPARKS OR
CIGARETTES; VENTILATE THE AREA WHEN RECHARGING INDOORS.
ALWAYS WEAR EYE PROTECTION WHEN WORKING IN THE PROXIMITY OF BATTERIES.
KEEP OUT OF REACH OF CHILDREN
- Remove the short closed tube and the caps, then
pour sulphuric acid into the cells using the type
specified for batteries with a specific gravity of
1.26, corresponding to 30 Bé at a minimum temperature of 15°C until the upper level is reached.
- Allow to stand for at least 2 hours, then top up the
level with sulphuric acid.
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Electrical system
- Within 24 hours, recharge using the special battery charger (single) or (multiple) at an intensity of
about 1/10 of the battery nominal capacity and until
the acid gravity is about 1.27, corresponding to 31
Bé and such values become steady.
- After charging, top up the acid (adding distilled
water). Close and clean carefully.
- After carrying out the operations above, install the
battery on the scooter, observing the connections
described in point 3) of paragraph "Battery recharge".
1 Keep the pipe in vertical position
2 Inspect visually
3 The float must be freed
Checking the electrolyte level
The electrolyte level must be checked frequently and must reach the upper level. Only use distilled
water, to restore this level. If it is necessary to add water too frequently, check the vehicle's electrical
system: the battery works overcharged and is subject to quick wear.
Charging status check
After topping-up the electrolyte level, check its density using special density gauge.
When the battery is charged, you should detect a density of 30 to 32 Bé corresponding to a specific
weight of 1.26 to 1.28 at a temperature of no lower than 15° C.
A density reading of less than 20° Bé indicates that the battery is completely flat and it must therefore
be recharged.
If the scooter is not used for a given time (1 month or more) it will be necessary to periodically recharge
the battery.
The battery runs down completely in the course of three months. When refitting the battery onto the
scooter pay attention not to invert the cables, bearing in mind that the earth (black) wire marked with
a (-) must be connected to the negative terminal whilst the other two red wires, marked with a (+) must
be attached to the positive, + terminal.
Battery recharge
WARNING
BEFORE RECHARGING THE BATTERY, REMOVE THE PLUGS OF EACH CELL. KEEP SPARKS
AND NAKED FLAMES AWAY FROM THE BATTERY WHILE RECHARGING.
Remove the battery from the vehicle removing the negative clamp first.
Normal bench charging must be performed using the special battery charger (single) or (multiple), setting the battery charge selector to the type of battery that requires recharging (i.e., at a current equal
to 1/10 of the battery rated capacity). Connections to the power supply source must be implemented
by connecting corresponding poles (+ to + and - to - ).
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Electrical system
The battery should always be kept clean, especially on its top side, and the terminals should be coated
with Vaseline.
CAUTION
NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY. USING
A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE
A FIRE.
CAUTION
ORDINARY AND DRINKING WATER CONTAINS MINERAL SALTS THAT ARE HARMFUL FOR
THE BATTERY. FOR THIS REASON, YOU MUST ONLY USE DISTILLED WATER.
CAUTION
CHARGE THE BATTERY BEFORE USE TO ENSURE OPTIMUM PERFORMANCE. FAILURE TO
CHARGE THE BATTERY ADEQUATELY BEFORE BEING PUT INTO OPERATION WILL LEAD TO
A PREMATURE FAILURE OF THE BATTERY.
Pump electrics check
Connect the tester positive probe to pin 4 of the
connector of the fuel pump control device, and the
negative probe to pin 3, making sure there is battery voltage as indicated in the table.
PUMP SUPPLY
Specification
Key set to «KEY ON»
Engine revs from 0 to 200 rpm
Engine revs from 200 to 1200 rpm
Engine revs from 1200 to 2000 rpm
Engine rpm ] 2000 r.p.m.
Remote controls check
To check the operation of a remote control:
1) Check that, given regular conditions, there is no
continuity between terminals 87 and 30.
2) Apply a 12V voltage to power terminals 86 and
85 of the remote control.
3) With the remote control fed, check that there is
continuity between terminals 87 and 30.
ELE SYS - 84
Desc./Quantity
Supply to the pump for 13 seconds
Always «OFF»
Always «ON»
0.2 seconds «ON»
9 seconds «OFF»
Always «ON»
Beverly Tourer 125
Electrical system
4) If these conditions are not met, the remote control is surely damaged and, therefore, it should be
replaced.
Switches check
To check buttons and switches, check that, according to their position, the continuity of contacts is
correct as indicated in the following charts.
KEY
Ar: Orange Az: Sky Blue Bi: White Bl: Blue Gi: Yellow Gr: Grey Ma: Brown Ne: Black Ro: Pink Rs:
Red Ve: Green Vi: Purple
ENGINE STOP SWITCH
STARTER BUTTON
LIGHT SWITCH
ELE SYS - 85
Electrical system
TURN INDICATOR SWITCH
HORN BUTTON
BUTTON FOR SADDLE ELECTRIC OPENING
HELMET COMPARTMENT LIGHT SWITCH
ELE SYS - 86
Beverly Tourer 125
Beverly Tourer 125
Electrical system
Connectors
ELECTRONIC IGNITION DEVICE CONNECTOR
1. Turn indicator switch (Blue-Black)
2. Pick-up (Green)
3. HV coil (Purple)
4. Battery powered (Red-Black)
5. Live power supply (Green-Red)
6. Immobilizer LED (Yellow)
7.Automatic starter (White-Black)
8. Ground (Black)
INSTRUMENT PANEL CONNECTOR «A»
1. Left turn indicator warning light (Pink)
2. Immobilizer (Yellow)
3. Battery powered (Red-Blue)
4. Coolant temperature gauge (Pink-Yellow)
5. Not connected
6. Fuel level transmitter (White-Green)
7. Right turn indicator warning light (White-Blue)
8. Low fuel warning light (Yellow-Green)
INSTRUMENT PANEL CONNECTOR «B»
1. High-beam warning light (Purple)
2. Ground (Black)
3. Oil pressure warning light (Brown)
4. Not connected
5. Live power supply (Red-Grey)
6. Instrument panel lighting (Yellow-Black)
VOLTAGE REGULATOR CONNECTOR
1. +Battery (Red-Black)
2. Magneto flywheel (Yellow)
3. Not connected
4. Magneto flywheel (Yellow)
5. Ground (Black)
6. Magneto flywheel (Yellow)
ELE SYS - 87
Electrical system
MAGNETO FLYWHEEL - PICK-UP CONNECTOR
1. Voltage regulator (Yellow)
2. Not connected
3. Voltage regulator (Yellow)
4. Oil pressure sensor (Brown)
5. Voltage regulator (Yellow)
6. Pick-up (Green)
FUEL ELECTRIC PUMP CONTROL DEVICE
CONNECTOR
1. Live power supply (Orange-Blue)
2. Not connected
3. Electric fuel pump negative (White-Black)
4. Electric fuel pump positive (Blue-Black)
5. Ground (Black)
6. Electronic ignition device (Purple)
FUEL ELECTRIC PUMP CONNECTOR
1. Fuel electric pump control device negative
(White-Black)
2. Fuel electric pump control device positive (BlueBlack)
AUTOMATIC STARTER CONNECTOR
1. Live power supply (Orange)
2. Electronic ignition device negative (WhiteBlack)
ELE SYS - 88
Beverly Tourer 125
Beverly Tourer 125
Electrical system
ELECTRIC FAN CONNECTOR
1. Thermoswitch (Green)
2. Battery powered (Red-Black)
FUEL LEVEL TRANSMITTER CONNECTOR
1. Fuel level indicator (White-Green)
2. Ground (Black)
3. Low fuel warning light (Yellow-Green)
ANTITHEFT DEVICE PRE-INSTALLATION
CONNECTOR
1. LHS Turn indicator bulbs (Pink)
2. RHS Turn indicator bulbs (White-Blue)
3. Ground (Black)
4. Battery powered (Red-Blue)
5. Live power supply (Red-Grey)
6. Helmet compartment light (Blue-Yellow)
7. Not connected
8. Not connected
ELE SYS - 89
INDEX OF TOPICS
ENGINE FROM VEHICLE
ENG VE
Beverly Tourer 125
Engine from vehicle
Exhaust assy. Removal
- Undo the two exhaust manifold fixings on the
head.
- Undo the three screws fixing the muffler to the
support arm.
- Remove the full muffler unit.
To refit, carry out the removal operations in reverse order, observing the prescribed tightening torques.
Locking torques (N*m)
Nuts fixing muffler to support arm 27 ÷ 30 Nut fixing muffler to cylinder head 16 ÷ 18
Removal of the engine from the vehicle
CAUTION
SUPPORT THE SCOOTER ADEQUATELY.
CAUTION
CARRY OUT THESE OPERATIONS WHEN THE ENGINE IS COLD.
WARNING
BE VERY CAREFUL WHEN HANDLING FUEL.
ENG VE - 91
Engine from vehicle
- Disconnect the battery.
- Remove the saddle, the side fairings and the
footrests.
- Get a container of suitable capacity, remove the
intake pipes and drain off the cooling system.
- Remove the rear wheel.
- Remove the left shock absorber lower retainer.
- Remove the rear brake calliper, release the pipes
from the four retainers on the engine crankcase.
- Remove the throttle control transmission from the
carburettor.
- Remove the indicated retainer clamp.
- Release the throttle control transmission and the
start-up pick-up connection from the cable guide
clamps.
ENG VE - 92
Beverly Tourer 125
Beverly Tourer 125
Engine from vehicle
- Disconnect the coolant outlet pipes, remove the
start-up pick-up, the fuel pipes, the retainer clamp
and the thermistor connector.
- Disconnect the starter motor and the generator
connector connections.
- Disconnect the spark plug HV wire.
- Remove the engine earthing.
- Unscrew the nut fixing the engine-side swinging
arm bolt.
ENG VE - 93
Engine from vehicle
Beverly Tourer 125
- Remove the engine-side swinging arm bolt.
- The engine is now free.
- When refitting the engine on the scooter, carry out the removal operations but in reverse order and
respect the locking torques indicated in the Characteristics Chapter.
-Check the engine oil level and if necessary top it up with the recommended type.
- Top-up the cooling circuit.
- Check the functioning of the accelerator and the electrical devices.
CAUTION
PAY PARTICULAR ATTENTION TO POSITIONING THE THROTTLE CONTROL TRANSMISSION
PROPERLY. CHECK THAT THERE IS A SMALL CLEARANCE WHEN THE VALVE IS IN ABUTMENT AGAINST THE SET SCREW.
ENG VE - 94
INDEX OF TOPICS
ENGINE
ENG
Engine
Automatic transmission
Transmission cover
- To remove the transmission cover it is necessary
to remove the plastic cover first, by inserting a
screwdriver in the slotted holes. Using the clutch
bell lock wrench shown in the figure, remove the
driven pulley shaft locking nut and washer.
Specific tooling
020423Y driven pulley lock wrench
- Remove the cap/dipstick from the engine oil filling
hole.
- Remove the ten screws.
- Remove the transmission cover.
If this operation is carried out directly on the vehicle, remove the cooling air supply coupling of the
transmission housing.
Air duct
- Remove the 4 screws and the housing.
ENG - 96
Beverly Tourer 125
Beverly Tourer 125
Engine
Removing the driven pulley shaft bearing
- Remove the clip from the inside of the cover.
- Remove the bearing from the crankcase by
means of:
Specific tooling
020376Y Adaptor handle
020375Y Adaptor 28 x 30 mm
020412Y 15 mm guide
Refitting the driven pulley shaft bearing
- Slightly heat the crankcase from the inside so as
not to damage the painted surface.
- Insert the bearing in its seat.
- Refit the seeger ring.
CAUTION
USE AN APPROPRIATE REST SURFACE TO AVOID DAMAGING THE COVER PAINT.
N.B.
ALWAYS REPLACE THE BEARING WITH A NEW ONE
UPON REFITTING.
Specific tooling
020376Y Adaptor handle
020357Y 32 x 35 mm adaptor
020412Y 15 mm guide
Baffle roller
Removal
Belt support roller (200 cm³ models only)
- Check that the roller does not show signs of wear
and that it turns freely.
- Remove the special fixing screw and the roller
together with the bearing.
ENG - 97
Engine
Refitting
- Heat the roller and insert the bearing using the
specific punch:
Specific tools:
Specific tooling
020455Y 10-mm guide
- Refit the roller with the special screw.
- Tighten to the specified torque.
- Refit the intake throat with the O-ring, the sump
sealing gasket and a the fan housing.
Locking torques (N*m)
Anti-flapping roller 12 - 16
Plastic roller
- Check that the roller does not show signs of wear
and that it turns freely.
- Remove the special clamping screws as indicated in the photograph
- Check the outside diameter of the roller does not
have defects that could jeopardise belt functioning
- For refitting, place the roller with the belt containment edge on the engine crankcase side
- Tighten the wrench to the prescribed torque.
Locking torques (N*m)
Anti-flapping roller 12 - 16
ENG - 98
Beverly Tourer 125
Beverly Tourer 125
Engine
Removing the driven pulley
- Remove the spacer, the clutch bell and the whole
driven pulley unit.
N.B.
THE UNIT CAN ALSO BE REMOVED WITH THE DRIVING
PULLEY MOUNTED.
Inspecting the clutch drum
- Check that the clutch bell is not worn or damaged.
- Measure the clutch bell inside diameter.
Characteristic
Max. value clutch bell
Max. value: Ø 134.5 mm
Clutch bell standard value
Standard value: Ø 134 - 134.2 mm
Checking the bell working surface eccentricity
- Install the bell on a driven pulley shaft using 2
bearings (inner diameter 15 and 17 mm).
- Lock with the original spacer and nut.
- Place the bell/shaft assembly on the support to
check the crankshaft alignment.
ENG - 99
Engine
- Using a feeler pin gauge and the magnetic base,
measure the bell eccentricity.
- Repeat the measurement in 3 positions (Central,
internal, external).
- If faults are found, replace the bell.
Specific tooling
020074Y Support base for checking crankshaft
alignment
020335Y Magnetic support for dial gauge
Characteristic
clutch bell inspection: Limit eccentricity.
Admissible limit eccentricity: 0.15 mm
Removing the clutch
Removing the clutch
Fit the driven pulley spring compressor specific
tool with medium length pins screwed in position
F from the tool internal side.
- Insert the adapter ring 8 in the pins.
- Assemble the driven pulley unit on the tool introducing the rivets heads in the adapter ring.
- Make sure that the clutch is perfectly inserted into
the adapter ring before proceeding to loosen/tighten the clutch nut.
- Use the special 46x55 wrench component n°9 to
remove the nut fixing the clutch in place.
- Separate the driven pulley components (Clutch,
fan and spring with plastic fitting).
CAUTION
THE TOOL MUST BE FIRMLY FIXED IN THE CLAMP AND
THE CENTRAL SCREW MUST BE BROUGHT INTO CONTACT WITH THE TOOL. EXCESSIVE TORQUE CAN CAUSE
THE SPECIFIC TOOL TO BUCKLE.
Specific tooling
020444Y009 46x55 Wrench
020444Y010 adapter ring
ENG - 100
Beverly Tourer 125
Beverly Tourer 125
Engine
Inspecting the clutch
- Check the thickness of the clutch mass friction
material.
- The masses must not show traces of lubricants;
otherwise, check the driven pulley unit seals.
N.B.
UPON RUNNING-IN, THE MASSES MUST EXHIBIT A CENTRAL CONTACT SURFACE AND MUST NOT BE DIFFERENT FROM ONE ANOTHER.
VARIOUS CONDITIONS CAN CAUSE THE CLUTCH TO
TEAR.
CAUTION
DO NOT OPEN THE MASSES USING TOOLS TO PREVENT
A VARIATION IN THE RETURN SPRING LOAD.
Characteristic
Check minimum thickness
1 mm
Pin retaining collar
- Simultaneously turn and pull the collar manually
to remove it.
N.B.
USE TWO SCREWDRIVERS IF YOU HAVE DIFFICULTY.
N.B.
BE CAREFUL NOT TO PUSH THE SCREW DRIVERS IN
TOO FAR TO AVOID DAMAGE THAT COULD ENDANGER
THE O-RING SEAL.
- Remove the four torque server pins and pull the
pulley halves apart.
ENG - 101
Engine
Removing the driven half-pulley bearing
- Check there are no signs of wear and/or noisiness; - Replace with a new one if there are.
- Remove the retaining ring using two flat blade
screwdrivers.
- Support the pulley bushing adequately from the
threaded side using a wooden surface.
- Using a hammer and pin, knock the ball bearing
out as shown in the figure.
- Support the pulley properly using the bell as
shown in the figure.
Specific tooling
001467Y035 Belle for OD 47-mm bearings
- Remove the roller bearing using the modular punch.
Specific tooling
020376Y Adaptor handle
020456Y Ø 24 mm adaptor
020363Y 20 mm guide
Inspecting the driven fixed half-pulley
- Measure the outer diameter of the pulley bushing.
- Check the contact surface with the belt to make
sure there are no flaws.
Characteristic
Half-pulley standard diameter
Standard diameter: Ø 40.985 mm
Half-pulley minimum diameter
Minimum admissible diameter Ø 40.96 mm
ENG - 102
Beverly Tourer 125
Beverly Tourer 125
Engine
Inspecting the driven sliding half-pulley
- Remove the two internal grommets and the two
O-rings.
- Measure the movable half-pulley bushing inside
diameter.
Characteristic
Movable driven half-pulley max. diameter
Max. diameter admitted: Ø 41.08 mm
Movable driven half-pulley standard diameter
Standard diameter: Ø 41.000 ÷ 41.035 mm
Refitting the driven half-pulley bearing
- Support the pulley bushing adequately from the
threaded side using a wooden surface.
- Fit a new roller sleeve as in the figure.
- For the fitting of the new ball bearing, follow the
example in the figure using a modular punch.
Fit the snap ring
WARNING
N.B.
FIT THE BALL BEARING WITH THE VISIBLE SHIELD
Specific tooling
020376Y Adaptor handle
020375Y Adaptor 28 x 30 mm
020424Y Driven pulley roller casing fitting
punch
ENG - 103
Engine
Refitting the driven pulley
- Insert the new oil guards and O-rings on the movable half-pulley.
- Lightly grease the O-rings (A) shown in the figure.
- Fit the half-pulley over the bushing using the appropriate tool
- Check that the pins are not worn and proceed to
refitting them in their slots.
- Refit the torque server closure collar.
Using a curved-spout grease gun, lubricate the
driven pulley assembly with approximately 6 g of
grease. Apply the grease through one of the holes
in the bushing until it comes out through the hole
on the opposite side. This operation is necessary
to avoid the presence of grease beyond the Orings.
N.B.
THE TORQUE SERVER CAN BE GREASED WHETHER
WITH BEARINGS FITTED OR WHEN THEY ARE BEING REPLACED; UNDERTAKING THE OPERATION WHEN THE
BEARINGS ARE BEING SERVICED MIGHT BE EASIER.
Specific tooling
020263Y Sheath for driven pulley fitting
Recommended products
AGIP GREASE SM 2 Grease for the tone wheel
revolving ring
Soap-based lithium grease containing NLGI 2 Molybdenum disulphide; ISO-L-XBCHB2, DIN
KF2K-20
ENG - 104
Beverly Tourer 125
Beverly Tourer 125
Engine
Inspecting the clutch spring
- Measure the length of the spring, while it is relaxed.
Characteristic
Standard length
106 mm
acceptable limit after use:
101 mm
Refitting the clutch
- Support the driven pulley spring compressor appropriate tool with the control screw in vertical axis.
- Arrange the tool with the medium length pins
screwed in position «F» on the inside.
- Insert the adapter ring 8 in the pins.
- Preassemble the cooling fan to the clutch in such
a way that the keying facets are aligned and the 3
pin heads (A) of the mass axis can be seen in full.
- Insert the clutch on the adapter ring.
- Lubricate the end of the spring that abuts against
the servo-system closing collar.
- Insert the spring with its plastic holder in contact
with the clutch.
- Insert the driving belt into the pulley unit according to their direction of rotation.
- Insert the pulley unit with the belt into the tool.
- Slightly preload the spring.
- Make sure that the clutch is perfectly inserted into
the adapter ring before proceeding to tighten the
clutch nut.
- Place the tool in the clamp with the control screw
on the horizontal axis.
- Fully preload the spring.
- Apply the clutch lock nut and tighten it to the
specified torque using the specific 46x55 spanner.
ENG - 105
Engine
- Loosen the tool clamp and insert the belt according to its direction of rotation.
- Lock the driven pulley again using the specific
tool.
- Preload the clutch return spring with a traction/
rotation combined action until it reaches the pulleys maximum opening and place the belt on the
minimum rolling diameter.
- Remove the driven pulley /belt unit from the tool.
N.B.
FOR DESIGN REASONS, THE NUT IS SLIGHTLY ASYMMETRIC; THE FLATTEST SURFACE SHOULD BE MOUNTED IN CONTACT WITH THE CLUTCH.
N.B.
DURING THE SPRING PRELOADING PHASE, BE CAREFUL NOT TO DAMAGE THE PLASTIC SPRING STOP AND
THE BUSHING THREADING.
N.B.
AN EXCESSIVE QUANTITY CAN DAMAGE THE CLUTCH
OPERATION.
Specific tooling
020444Y011 adapter ring
020444Y009 46x55 Wrench
Locking torques (N*m)
Clutch unit nut on driven pulley 55 ÷ 60
Refitting the driven pulley
- Reassemble the clutch bell and spacer.
ENG - 106
Beverly Tourer 125
Beverly Tourer 125
Engine
Drive-belt
- Check that the driving belt is not damaged.
- Check the width of the belt.
Characteristic
Driving belt - minimum width:
21.5 mm
Driving belt - standard width:
22.5 ± 0.2 mm
During the wear checks foreseen in the scheduled
maintenance services at 6,000 km; 18,000 km;
etc., check that the rim bottom of the toothing does
not show signs of incisions or cracking (see figure):
The rim bottom of the tooth must not have incisions
or cracking; if it does, change the belt.
Removing the driving pulley
- With the appropriate tool, remove the nut with the
built-in Belleville washer, the drive common to the
kick-starter version, and the steel washer.
- Remove the fixed driving half-pulley.
- Remove the steel washer separating from the
bushing.
Specific tools:
Specific tooling
020368Y driving pulley lock wrench
ENG - 107
Engine
Inspecting the rollers case
- Check that the internal bushing shown in the figure is not abnormally worn and measure inner
diameter A.
- Measure outer diameter B of the pulley sliding
bushing shown in the figure.
- Check that the rollers are not damaged or worn.
- Check the guide shoes for the variator back-plate
are not worn.
- Check the wear of the roller housings and of the
belt contact surfaces on both pulley halves.
- Check that stationary driving pulley does not
show signs of abnormal wear on the grooved edge
and on the surface in contact with the belt.
- Check that the O-ring is not pushed out of shape.
CAUTION
DO NOT LUBRICATE OR CLEAN SINTERED BUSHINGS
Characteristic
Movable driving half-pulley bushing: Standard
Diameter
26.000 - 26.021 mm
Movable driving half-pulley bushing: Maximum allowable diameter
Ø 26.12 mm
Sliding bushing: Standard Diameter
Ø 25.959 ÷ 25.98 mm
Sliding bushing: Minimum admissible diameter
Ø 25.95 mm
Roller: Standard Diameter
Ø 18.9 ÷ 19.1 mm
Roller: Minimum diameter permitted
Ø 18.5 mm
ENG - 108
Beverly Tourer 125
Beverly Tourer 125
Engine
Refitting the driving pulley
- Preassemble the movable half-pulley with the
roller contrast plate by putting the rollers in their
housings with the larger support surface touching
the pulley according to the direction of rotation.
- Check that the roller contact plate does not have
flaws and is not damaged on the grooved edge.
- Mount the complete bushing unit on the driving
shaft.
- Fit the driven pulley/Clutch/belt unit on the engine.
- Correctly refit the previously removed Bendix
back to its position.
- Reassemble the parts of the unit (internal lining,
fixed half-pulley, external lining, drive and nut),
spread Loctite 243 Quick Set threadlock on the
thread and tighten the nut to the prescribed torque.
- Avoid the half-pulley rotation with the appropriate
stop key tool..
ENG - 109
Engine
- Rotate the engine manually until the belt is slightly taut.
CAUTION
IT IS EXTREMELY IMPORTANT THAT THE BELT IS PERFECTLY FREE WHEN THE FIXED DRIVING HALF-PULLEY
IS ASSEMBLED. THIS IS TO AVOID CARRYING OUT A
WRONG TIGHTENING OF THE DRIVING HALF-PULLEY.
Specific tooling
020368Y driving pulley lock wrench
Locking torques (N*m)
Drive pulley nut 75 ÷ 83
Refitting the transmission cover
- Check the presence of the 2 centring dowels and
the correct installation of the sealing gasket for the
oil sump on the transmission cover.
- Replace the cover tightening the 10 screws at the
specified torque.
- Refit the oil loading cap/bar.
- refit the steel washer and the driven pulley nut.
- Tighten the nut to the prescribed torque using the
lock wrench and the torque wrench tools.
- Replace the plastic cover.
Specific tooling
020423Y driven pulley lock wrench
Locking torques (N*m)
Transmission cover screws 11 ÷ 13 Driven pulley shaft nut 54 ÷ 60
End gear
ENG - 110
Beverly Tourer 125
Beverly Tourer 125
Engine
Removing the hub cover
- Empty the rear hub through the oil drainage plug.
- Remove the 7 flanged screws indicated in the
figure.
- Remove the hub cover and its gasket.
Removing the wheel axle
- Remove the wheel axis complete with gear.
- Remove the intermediate gear.
Removing the hub bearings
- Check the state of the bearings being examined
(wear, clearance and noisiness). If faults are detected, do the following.
- Use the specific bearing extractor to remove the
three 15 mm bearings (2 in the crankcase and 1 in
the hub cover).
Specific tooling
001467Y013 Pliers to extract ø 15-mm bearings
ENG - 111
Engine
Removing the wheel axle bearings
- Take out the clip on the outside of the gearbox
cover.
- Support the hub cover and expel the bearing.
By means of the appropriate tools, remove the oil
guard as in the figure.
Specific tooling
020376Y Adaptor handle
020477Y Adaptor 37 mm
020483Y 30 mm guide
020359Y 42x47-mm adaptor
020489Y Hub cover support stud bolt set
ENG - 112
Beverly Tourer 125
Beverly Tourer 125
Engine
Removing the driven pulley shaft bearing
- As you need to remove the driven pulley shaft, its
bearing and oil guard, remove the transmission
cover as described above.
- Extract the driven pulley shaft from its bearing.
- Remove the oil guard using a screwdriver, working from inside the bearing and being careful not
to damage the housing, make it come out of the
belt transmission side.
- Remove the seeger ring shown in the figure
Remove the driven pulley shaft bearing using the
modular punch.
Specific tooling
020376Y Adaptor handle
020375Y Adaptor 28 x 30 mm
020363Y 20 mm guide
Inspecting the hub shaft
- Check the three shafts for wear or distortion of
the toothed surfaces, the bearing housings, and
the oil seal housings.
- In case of anomalies, replace the damaged components.
Inspecting the hub cover
- Check that the fitting surface is not dented or distorted.
- Check the bearing bearings.
- In case of anomalies, replace the damaged components.
ENG - 113
Engine
Refitting the wheel axle bearing
- Support the hub cover on a wooden surface.
- Heat the crankcase cover with the specific heat
gun.
- Fit the wheel shaft bearing with a modular punch
as shown in the figure.
- Fit the seeger ring.
- Fit the oil guard with seal lip towards the inside
of the hub and place it flush with the internal surface by means of the appropriate tool used from
the 52 mm side.
The 52 mm side of the adapter must be turned towards the bearing.
Specific tooling
020376Y Adaptor handle
020360Y Adaptor 52 x 55 mm
020483Y 30 mm guide
ENG - 114
Beverly Tourer 125
Beverly Tourer 125
Engine
Refitting the hub cover bearings
For the fitting of the hub box bearings the engine
crankcase and the cover must be heated with the
special heat gun.
- The three 15 mm bearings must be fitted using
the appropriate tools.
- The 42-mm side of the adapter must be turned
towards the bearing.
Specific tooling
020150Y Air heater support
020151Y Air heater
020376Y Adaptor handle
020359Y 42x47-mm adaptor
020412Y 15 mm guide
N.B.
TO FIT THE BEARING ON THE COVER, SUPPORT THE COVER WITH THE STUD BOLT SET.
- Refit the driven pulley shaft bearing with a modular punch as shown in the figure.
N.B.
IF THE BEARING HAS AN ASYMMETRICAL BALL RETAINER, PLACE IT SO THAT THE BALLS ARE VISIBLE FROM
THE HUB INNER SIDE.
Specific tooling
020376Y Adaptor handle
020359Y 42x47-mm adaptor
020363Y 20 mm guide
N.B.
WHEN FITTING THE BEARINGS ON THE ENGINE CRANKCASE, SUPPORT THE CRANKCASE
PREFERABLY ON A SURFACE TO ALLOW THE BEARINGS TO BE DRIVEN VERTICALLY.
- Refit the seeger ring with the opening facing the bearing and fit a new oil guard flush with the crankcase
from the pulley side.
Refitting the hub bearings
- Install the three shafts in the engine crankcase as shown in the figure.
ENG - 115
Engine
Refitting the ub cover
- Fit a new gasket together with the centring dowels.
- Seal the gasket of the breather pipe using black
silicone sealant.
- Fit the gearbox cover, making sure the breather
pipe is in the correct position.
- Place the 3 shortest screws, identifiable by their
different colour, as shown in the figure.
- Fasten the breather pipe support bracket with the
lower short screw.
- Assemble the remaining 4 screws and tighten the
7 screws to the prescribed torque.
Locking torques (N*m)
Rear hub cover screws 24 ÷ 27
ENG - 116
Beverly Tourer 125
Beverly Tourer 125
Engine
Flywheel cover
Removing the hub cover
- Remove the two clamps, the two couplings and
empty the cooling system.
- Remove the 4 retainers and the flywheel cover
Removing the stator
- Remove the electric terminal of the minimum oil
pressure switch.
- Remove the two Pick-Up screws and the one for
the wiring harness bracket as well as the two stator
fixing screws shown in the figure.
- Remove the stator and its wiring.
ENG - 117
Engine
Refitting the stator
- Refit the stator and flywheel carrying out the removal procedure in reverse, tightening the retainers to the specified torque.
- Place the cable harness as shown in the figure.
- Stator screws and Pick-Up
N.B.
THE PICK-UP WIRE SHOULD BE POSITIONED BETWEEN
THE UPPER SCREW AND THE REFERENCE PIN AS
SHOWN IN THE DETAIL DRAWING.
Locking torques (N*m)
Stator assembly screws (°) 3 ÷ 4
Refitting the flywheel cover
- Place the flywheel with the top dead centre mark
aligned with the crankcase.
- Place the flywheel cover by aligning the reference
marks of the drive and the crankcase cover.
- Reassemble the cover on the engine, placing the
three connectors in the drive for the water pump.
- Carry out the steps in the reverse order from the
dismantling procedure.
CAUTION
TAKE CARE TO CORRECTLY POSITION THE FLYWHEEL
CONNECTOR. MAKE SURE THE CENTRING DOWELS ARE
PRESENT.
Flywheel and starting
ENG - 118
Beverly Tourer 125
Beverly Tourer 125
Engine
Removing the starter motor
- Remove the two screws indicated in the figure.
- Take the starter motor out of its seat
Removing the flywheel magneto
- Remove the water pump shaft and crankshaft
spline clip
- Line up the two holes in the flywheel as shown in
the photo
- Screw in the guide bushing that is part of the
special flywheel stop tool on the flywheel as shown
in the photo.
ENG - 119
Engine
Beverly Tourer 125
- Insert the special flywheel stop tool on the flywheel as shown in the photo
Specific tooling
020627Y Flywheel lock wrench
- 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 on
extraction
- Screw the extractor onto the flywheel and extract
it as shown in the photograph
Specific tooling
020467Y Flywheel extractor
- Lock the rotation of the Flywheel with the calliper
spanner tool.
- Remove the nut.
- Take out the flywheel.
CAUTION
THE USE OF A CALLIPER SPANNER OTHER THAN THE
ONE SUPPLIED COULD DAMAGE THE STATOR COILS
Specific tooling
020565Y Flywheel lock calliper spanner
008564Y Flywheel extractor
Inspecting the flywheel components
- Check the integrity of the internal plastic parts of the flywheel and the Pick-Up control plate.
ENG - 120
Beverly Tourer 125
Engine
Refitting the free wheel
- Make sure the freewheel faying surfaces are in good condition.
- Thoroughly clean the free wheel to remove LOCTITE residue.
- Degrease the threading of the holes in the free wheel and the clamping screws.
- Apply the recommended product to the end of the screws.
Recommended products
Loctite 243 Medium strength threadlock
Loctite 243 medium-strength threadlock
- Fit the freewheel on the magneto flywheel making
sure that the ground side is in contact with the flywheel itself, i.e. with wheel seeger ring visible.
- Lock the six clamping screws in criss-cross fashion to the prescribed torque.
Locking torques (N*m)
Screw fixing freewheel to flywheel 13 ÷ 15
- Oil the free wheel "rollers".
Refitting the flywheel magneto
- Remove the freewheel retaining plate indicated
in the photograph
- Remove the transmission gear and the freewheel
ENG - 121
Engine
- Insert the free wheel on the flywheel as shown in
the photo
- Then refit the flywheel with free wheel and transmission gear
- Using the special flywheel stop tool, tighten up
the flywheel fixing nut to the prescribed torque
-Refit the retention plate
Specific tooling
020627Y Flywheel lock wrench
Locking torques (N*m)
Flywheel nut 94 ÷ 102
- Fit the flywheel being careful to insert the key
properly.
- Lock the flywheel nut to the prescribed torque
- Check that the Pick-Up air gap is between 0.34
÷ 0.76 mm.
The air gap cannot be modified when assembling
the Pick-Up.
Different values result from deformations visible
on the Pick-Up support.
N.B.
A VARIATION IN THE AIR GAP DISTANCE MODIFIES THE
IGNITION SYSTEM IDLE SPEED
Specific tooling
020565Y Flywheel lock calliper spanner
Locking torques (N*m)
Flywheel nut 54 ÷ 60
ENG - 122
Beverly Tourer 125
Beverly Tourer 125
Engine
Refitting the starter motor
- Fit a new O-ring on the starter motor and lubricate
it.
- Fit the starter on the crankcase, locking the two
screws to the prescribed torque.
Locking torques (N*m)
Starter motor screws 11 ÷ 13
Cylinder assy. and timing system
Removing the intake manifold
- Remove the flywheel cover completely as described in the flywheel cover section.
- Loosen the 3 crews and remove the intake manifold.
N.B.
TAMPERPROOF SCREWS ARE SUPPLIED WITH 125 CC
MODELS.
Removing the rocker-arms cover
- Remove the 5 screws indicated in the figure
ENG - 123
Engine
Removing the timing system drive
- Remove the parts listed below first: transmission
cover, drive pulley with belt, oil sump with spring
and by-pass piston, oil pump pulley cover, O-ring
on the crankshaft and the sprocket wheel separation washer.
- Remove the tappet cover.
- Remove the central screw fastener and the automatic valve-lifter retaining cover, as shown in the
figure.
- Remove the return spring of the automatic valve
lifter unit and the automatic valve lifter unit and its
end of stroke washer.
- Loosen the central screw on the tensioner first.
- Remove the two fixings shown in the figure.
- Remove the tensioner with its gasket.
- Remove the internal hex screw and the counterweight shown in the figure.
ENG - 124
Beverly Tourer 125
Beverly Tourer 125
Engine
- Remove the camshaft control pulley with its
washer.
- Remove the command sprocket wheel and the
timing chain.
- Remove the screws indicated in the figure, the
spacer bar and the tensioner slider.
The chain tensioning pad must be removed from
the transmission side. As regards the lower chain
guide pad, it may only be removed after the head
has been removed.
N.B.
IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO ENSURE THAT THE INITIAL DIRECTION OF ROTATION IS
MAINTAINED.
Removing the cam shaft
- Remove the two screws and the cam shaft retainer shown in the diagram.
- Remove the cam shaft.
- Remove the pins and the rocker arms from the
flywheel side holes.
N.B.
IN CASE OF NEED, THE HEAD MAY BE REMOVED WITH
THE CAMSHAFT, PINS, ROCKING LEVERS AND FIXING
BRACKET. THE HEAD CAN ALSO BE REMOVED WITHOUT REMOVING THE CHAIN AND THE DRIVING SHAFT
CHAIN TIGHTENER.
ENG - 125
Engine
Removing the cylinder head
- Remove the spark plug.
- Remove the 2 side fixings shown in the figure.
- Loosen the 4 head-cylinder fastening nuts in two
or three stages and in criss-cross fashion.
- Remove the head, the two centring dowels and
the gasket.
N.B.
IN CASE OF NEED, THE HEAD MAY BE REMOVED WITH
THE CAMSHAFT, PINS, ROCKING LEVERS AND FIXING
BRACKET. THE HEAD CAN ALSO BE REMOVED WITHOUT REMOVING THE CHAIN AND THE DRIVING SHAFT
CHAIN TIGHTENER.
ENG - 126
Beverly Tourer 125
Beverly Tourer 125
Engine
Removing the valves
- Using the appropriate tool fitted with an adaptor,
remove the cotters, caps, springs and valves.
- Remove the oil guards with the appropriate tool.
- Remove the lower spring supports.
CAUTION
REPLACE THE VALVES IN SUCH A WAY AS TO RECOGNISE THEIR ORIGINAL POSITION ON THE HEAD.
Specific tooling
020382Y011 adapter for valve removal tool
020382Y Valve cotters equipped with part 012
removal tool
020306Y Punch for assembling valve seal
rings
Removing the cylinder - piston assy.
- Remove the chain guide pad.
- Pull out the cylinder.
- Remove the cylinder base gasket.
- Remove the two stop rings, the wrist pin and the piston.
- Remove the piston seals.
CAUTION
TO AVOID DAMAGING THE PISTON, SUPPORT IT WHILE REMOVING THE CYLINDER.
N.B.
BE CAREFUL NOT TO DAMAGE THE SEALING RINGS DURING REMOVAL.
ENG - 127
Engine
Inspecting the small end
- Measure the internal diameter of the small end
using an internal micrometer.
N.B.
REPLACE THE CRANKSHAFT IF THE DIAMETER OF THE
ROD SMALL END EXCEEDS THE STANDARD DIAMETER
OR IT SHOWS SIGNS OF WEAR OR OVERHEATING.
Characteristic
Rod small end check-up: Maximum diameter
15.030 mm
Rod small end check-up: Standard diameter
15 +0.015+0.025 mm
ENG - 128
Beverly Tourer 125
Beverly Tourer 125
Engine
Inspecting the wrist pin
- Measure the outside diameter of the gudgeon
pin.
- Calculate the coupling clearance between pin
and connecting rod end.
Characteristic
Pin diameter: Standard clearance
0.015 ÷ 0.029 mm
Pin diameter Standard diameter
14.996 - 15.000 mm
Inspecting the piston
- Measure the diameter of the wrist pin seat on the
piston.
- Calculate the piston pin coupling clearance.
- Measure the outside diameter of the piston, perpendicular to the gudgeon pin axis.
- Measure at 41.1 mm from the piston crown in the
position shown in the figure.
- Carefully clean the seal housings.
- Measure the coupling clearance between the
seal rings and the grooves using suitable sensors,
as shown in the diagram.
- If the clearance is greater than that indicated in
the table, replace the piston.
N.B.
THE PIN HOUSINGS HAVE 2 LUBRICATION CHANNELS.
FOR THIS REASON MEASUREMENT OF THE DIAMETER
MUST BE CARRIED OUT ACCORDING TO THE AXIS OF
THE PISTON.
Characteristic
Wrist pin seat on the piston: Standard diameter
15.001 ÷ 15.006 mm
Diameter of the wrist pin seat on the piston:
Standard clearance
0.001 ÷ 0.010 mm
piston diameter
56.945 ÷ 56.973 mm
Fitting clearance
ENG - 129
Beverly Tourer 125
Engine
Top piston ring - standard coupling clearance
0.025 ÷ 0.07 mm Top piston ring - maximum clearance allowed after use 0.08 mm Middle piston
ring - standard coupling clearance 0.015 - 0.06 mm
Middle piston ring - maximum clearance allowed after use 0.07 mm oil scraper ring - standard coupling clearance 0.015 - 0.06 mm oil scraper
ring - maximum clearance allowed after use
0.07 mm
Inspecting the cylinder
- Using a bore meter, measure the inner cylinder
diameter at three different points according to the
directions shown in the figure.
- 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 (A-A,
B-B, C-C, D-D).
- The cylinder rectifying operation should be carried out with a surfacing that respects the original
angle.
- The cylinder surface roughness should be 0.9
micron.
- This is indispensable for a good seating of the
sealing rings, which in turn minimises oil consumption and guarantees optimum performance.
- The pistons are oversized due to cylinder grinding and are subdivided into three categories- 1st,
2nd, 3rd corresponding to 0.2-0.4-0.6 mm oversi-
ENG - 130
Beverly Tourer 125
Engine
zes. They are also classified into 4 categories AA, B-B, C-C, D-D.
Characteristic
cylinder: standard diameter
56.997 - 57.025 mm (at 41 mm)
Maximum allowable run-out:
0.05 mm
Inspecting the piston rings
Sealing rings
- Alternately insert the three sealing rings into the cylinder, in the area where it retains its original diameter. Using the piston, insert the rings perpendicularly to the cylinder axis.
- Measure the opening (see figure) of the sealing rings using a feeler gauge.
- If any measurements are greater than specified, replace the piston rings.
N.B.
BEFORE REPLACING ONLY THE PISTON RINGS, ENSURE THAT THE CLEARANCE BETWEEN
THE PISTON RINGS AND THE PISTON RING GROOVES, AND BETWEEN THE PISTON AND THE
CYLINDER, IS AS SPECIFIED. IN ANY CASE, NEW PISTON RINGS USED IN COMBINATION WITH
A USED CYLINDER MAY HAVE DIFFERENT BEDDING CONDITIONS THAN THE STANDARD.
Characteristic
Top piston ring
Standard opening: 0.15 ÷ 0.30 mm
Middle piston ring
Standard opening: 0.10 ÷ 0.30 mm
scraper ring
Standard opening: 0.15 ÷ 0.35 mm
ENG - 131
Engine
Removing the piston
- Install piston and wrist pin onto the connecting
rod, aligning the piston arrow the arrow facing towards the exhaust.
- Fit the wrist pin stop ring onto the appropriate tool
- With opening in the position indicated on the tool
S = left
D= right
- Place the wrist pin stop ring into position using a
punch
- Fit the wrist pin stop using the plug as shown in
the figure
N.B.
THE TOOL FOR INSTALLING THE STOP RINGS MUST BE
USED MANUALLY.
CAUTION
USING A HAMMER MIGHT DAMAGE THE STOPS' HOUSING.
Specific tooling
020454Y Tool for fitting piston pin stops (200 250)
Choosing the gasket
Characteristic
Compression ratio
12 ± 0.5: 1
ENG - 132
Beverly Tourer 125
Beverly Tourer 125
Engine
Measurement «A» to be taken, is a value of piston protrusion. It indicates by how much the plane formed
by the piston crown protrudes from the plane formed by the upper part of the cylinder. The further the
piston protrudes from the cylinder, the thicker the base gasket to be used (to restore the compression
ratio) and vice versa.
N.B.
NO GASKETS AND SEALS SHOULD BE ASSEMBLED BETWEEN THE CRANKCASE AND CYLINDER AND THE DIAL GAUGE EQUIPPED WITH SUPPORT SHOULD BE SET TO ZERO FOR
MEASUREMENT «A» TO BE TAKEN WITH THE PISTON AT TOP DEAD CENTRE POSITION AND
ON A RECTIFIED PLANE.
MODELS WITH METAL HEAD GASKET (0.3)
Name
Shimming - Cylinder 67.8 - Head gasket
0.3 - Base gasket 0.4
Shimming - Cylinder 67.8 - Head gasket
0.3 - Base gasket 0.6
Measure A
1.40 ÷ 1.65
Thickness
0.4 ± 0.05
1.65 ÷ 1.90
0.6 ± 0.05
ENG - 133
Engine
Beverly Tourer 125
Refitting the piston rings
Fitting the sealing rings
- Place the oil scraper spring on the piston.
- Refit the oil scraper ring with the join of spring
ends on the opposite side from the ring gap and
the word 'TOP' towards the crown of the piston.
The chamfered side of the oil scraper ring should
always be facing the piston crown.
- Fit the middle piston ring with the identification
letter facing the crown of the piston. In any case,
the step must be facing opposite the piston top.
- Fit the top piston ring with the word 'TOP' or the
reference mark facing the crown of the piston.
- Offset the piston ring gaps on the three rings by
120° to each other as shown in the figure.
- Lubricate the components with engine oil.
N.B.
THE TWO PISTON RINGS ARE MADE WITH A TAPERED
CYLINDRICAL CONTACT CROSS-SECTION. THIS IS TO
ACHIEVE A BETTER BEDDING.
Refitting the cylinder
- Insert the cylinder base gasket with the thickness determined above.
- Using the fork support and the piston ring retaining band, refit the cylinder as shown in the figure.
N.B.
BEFORE FITTING THE CYLINDER, CAREFULLY BLOW OUT THE LUBRICATION DUCT AND OIL
THE CYLINDER BARREL.
Specific tooling
020426Y Piston fitting fork
020393Y Piston fitting band
020287Y Clamp to assemble piston on cylinder
ENG - 134
Beverly Tourer 125
Engine
Inspecting the cylinder head
- Using a trued bar and feeler gauge check that the
cylinder head surface is not worn or distorted.
Maximum allowable run-out: 0.05 mm
- Check that the camshaft and the rocker pin capacities exhibit no wear.
- Check that the cylinder head cover surface, the
intake manifold and the exhaust manifold are not
worn.
Characteristic
bearing «A»
Ø 12.000 - 12.018 mm
bearing «B»
Ø 20.000 ÷ 20.021 mm
bearing «C»
Ø 37.000 - 37.025 mm
ENG - 135
Engine
Inspecting the timing system components
- Check that the guide shoe and the tensioner shoe
are not worn out.
- Ensure that the camshaft control pulley chain assembly and the sprocket wheel are not worn.
- If you encounter wear, replace the parts or, if the
chain, sprocket wheel and pulley are worn replace
the whole assembly.
- 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
assembly.
Inspecting the valve sealings
- 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.
ENG - 136
Beverly Tourer 125
Beverly Tourer 125
Engine
Inspecting the valve housings
- Check the width of the imprint on the valve
seat«V» wear limit max. 1.6 mm.
- Remove any carbon formation from the valve
guides.
- Measure the inside diameter of each valve guide.
- Take the measurement at three different heights
in the rocker arm push direction.
- If the width of the impression on the valve seat or
the diameter of the valve guide exceed the specified limits, replace the cylinder head.
Characteristic
Valve seat wear Intake guide
limit accepted: 5.022
Valve seat wear Intake guide
Standard diameter: 5.000 ÷ 5.012 mm
Valve seat wear Exhaust guide
Accepted limit 5.022
Valve seat wear Exhaust guide
Standard diameter: 5.000 ÷ 5.012 mm
Inspecting the valves
- Measure the width of the sealing surface on the
valve seats and on the valves.
Sealing surface width: After use: Intake and exhaust: 1.6 mm
- If any of the sealing surfaces on the valves is
wider than the specified limit or is damaged in one
or more points, or curved, replace the valve with a
new one.
CAUTION
DO NOT REVERSE THE FITTING POSITIONS OF THE
VALVES (RIGHT - LEFT).
Characteristic
Valve wear check Standard: Intake and exhaust:
0.99 - 1.27 mm
- Measure the diameter of the valve stems in the three positions indicated in the diagram.
ENG - 137
Engine
Beverly Tourer 125
- Calculate the clearance between valve and valve guide.
- Check that there are no signs of wear on the surface of contact with the articulated register terminal.
- If the checks above give no failures, you can use the same valves. For best sealing results, it is
advisable to grind the valves. Grind the valves gently with a fine-grained lapping compound. During the
grinding, keep the cylinder head with the valve axes in a horizontal position. This will prevent the lapping
compound residues from penetrating between the valve stem and the guide (see figure).
CAUTION
TO AVOID SCORING THE FAYING SURFACE, DO NOT KEEP ROTATING THE VALVE WHEN NO
LAPPING COMPOUND IS LEFT. CAREFULLY WASH THE CYLINDER HEAD AND THE VALVES
WITH A SUITABLE PRODUCT FOR THE TYPE OF LAPPING COMPOUND BEING USED.
N.B.
DO NOT CHANGE THE POSITIONS THE VALVES ARE FITTED IN
Characteristic
Valve check standard length
Outlet: 94.4 mm
Valve check standard length
Inlet: 94.6 mm
Valve check Maximum admissible clearance
Outlet: 0.072 mm
Valve check Maximum admissible clearance
Inlet: 0.062 mm
Valve check standard clearance
Outlet: 0.025 ÷ 0.052 mm
Valve check standard clearance
Inlet: 0.013 ÷ 0.040 mm
Valve check Minimum admissible diameter
Outlet: 4.95 mm
Valve check Minimum admissible diameter
Inlet: 4.96 mm
Valve check Standard diameter:
Inlet: 4.972 ÷ 4.987 mm
Valve check Standard diameter:
Outlet: 4.96 ÷ 4.975 mm
ENG - 138
Beverly Tourer 125
Engine
Inspecting the springs and half-cones
- Check that the upper spring caps and the cotter
halves show no signs of abnormal wear.
ENG - 139
Engine
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 seals.
- Fit the valves, the springs and the caps. Using
the appropriate tool with adapter, compress the
springs and insert the cotters in their seats.
N.B.
DO NOT CHANGE THE VALVE FITTING POSITION. FIT THE
VALVE SPRINGS WITH THE REFERENCE COLOUR ON
COTTER SIDE (TURNS WITH GREATER PITCH).
Specific tooling
020306Y Punch for assembling valve seal
rings
020382Y Valve cotters equipped with part 012
removal tool
020382Y011 adapter for valve removal tool
Inspecting the cam shaft
- Inspect the cam shaft for signs of abnormal wear
on the cams.
- Check the cam height.
- Check there is no wear on the cam shaft retaining
plate and its associated groove on the cam shaft.
- If any of the above dimensions are outside the
specified limits, or there are signs of excessive
wear, replace the defective components with new
ones.
- Check there are no signs of wear on the automatic valve-lifter cam, or the end-of stroke roller,
or the rubber buffer on the automatic valve-lifter
retaining cover.
- Check that the valve lifting spring has not yielded.
- Replace any defective or worn components.
- Check the rocker pins do not show signs of wear
or scoring.
ENG - 140
Beverly Tourer 125
Beverly Tourer 125
Engine
- Measure the internal diameter of each rocker
arm.
Check there are no signs of wear on the pad from
contact with the cam and on the jointed adjustment
plate.
Characteristic
Internal rocker arm diameter: Standard diameter
Diameter 12.000 - 12.011 mm
Rocking lever pin diameter: Standard diameter
Diameter 11.977 - 11.985 mm
Cam shaft check: Maximum admissible axial
clearance
0.42 mm
Cam shaft check: Standard axial clearance:
0.11 - 0.41 mm
Cam shaft check: Standard height
Outlet: 29.209 mm
Cam shaft check: Standard height
Inlet: 30.285 mm
Cam shaft check: Minimum admissible diameter
Bearing B diameter: 19.950 mm
Cam shaft check: Minimum admissible diameter
Bearing A Ø: 36.94 mm
Cam shaft check: Standard diameter
Bearing B diameter: 19.959 ÷ 19.98 mm
Cam shaft check: Standard diameter
Bearing A Ø: 36.95 ÷ 36.975 mm
ENG - 141
Engine
Refitting the head and timing system components
- Fit the timing chain guide pad.
- Insert the centring dowel between the cylinder
head to the cylinder, fit the cylinder head gasket
and the cylinder head.
- Lubricate the stud bolt threading.
- Tighten up the nuts to a pre-torque of 7±1 N·m
- Rotate by a 180° angle (2 rotations of 90° each)
- To carry out the operations described above, follow the tightening sequence in the figure.
- Fit the two screws on the outside of the timing
chain side and tighten them to the specified torque.
N.B.
BEFORE INSTALLING THE HEAD, MAKE SURE THAT THE
LUBRICATION CHANNEL IS CLEAN USING A COMPRESSED AIR JET.
Locking torques (N*m)
Timing chain tensioner support screw 11 ÷ 13
Assemble the lower timing chain sprocket wheel
on the crankshaft, with the chamfer facing the insertion side.
- Loop the timing chain around the sprocket on the
crankshaft.
- Fit the chain tensioner slider from the cylinder
head side.
- Fit the spacer and the screw fastener.
- Tighten the screws to the prescribed torque.
Locking torques (N*m)
ENG - 142
Beverly Tourer 125
Beverly Tourer 125
Engine
Slider screw 10 ÷ 14 Nm
Fit the pins and rocking levers.
- Lubricate the two rocking levers through the
holes at the top.
- Lubricate the 2 bearings and insert the cam shaft
in the cylinder head with the cams corresponding
to the rockers.
- Insert the retention plate and tighten the two
screws shown in the figure to the prescribed torque.
Locking torques (N*m)
Plate screws 4 ÷ 6 Nm
Insert the spacer on the cam shaft.
- Rotate the engine so that the piston is at top dead
centre, using the reference marks on the flywheel
and the crankcase.
- Holding this position insert the chain on the camshaft control pulley.
- Insert the pulley on the cam shaft while keeping
the reference 4V in correspondence with the reference mark on the head.
- Assemble the counterweight with the corresponding fixing screw and tighten to the prescribed
torque.
Locking torques (N*m)
Counterweight screw 7 ÷ 8.5
Fit the end-of stroke ring on the valve-lifting mass
and fit the automatic valve-lifting cam to the camshaft.
N.B.
LUBRICATE WITH GREASE THE END-OF-STROKE RING
IN ORDER TO AVOID ACCIDENTAL LEAKS THAT MAY
FALL INTO THE ENGINE. ASSEMBLE THE AUTOMATIC
VALVE-LIFTER RETURN SPRING. DURING THIS OPERATION THE SPRING MUST BE LOADED AT APPROXIMATELY 180°.
ENG - 143
Beverly Tourer 125
Engine
Assemble the limiting bell using the counterweight
fixing screw as a reference.
- Tighten the clamping screw to the prescribed torque.
Locking torques (N*m)
Limiting bell screw 11 ÷ 15 Nm
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 prescribed torque.
Insert the chain tensioning screw, together with the
spring and washer, tightening it to the prescribed
torque.
Locking torques (N*m)
Tensioner screws 11 ÷ 13 Tensioner cover 5 ÷ 6
Nm
Adjust valve clearance
- Fit the spark plug.
Electrode distance 0.8 mm
Locking torques (N*m)
Spark plug 12 ÷ 14
Refit the cylinder head cover, tightening the 5 screws to the prescribed torque. Make sure the gasket
is positioned properly.
Remove the flywheel cover completely as already described in the flywheel chapter.
- Reassemble the oil pump control, the chain compartment cover, the by-pass and the oil sump as
described in the lubrication chapter.
- Reassemble the driving pulley, the belt and the transmission cover as described in the transmission
chapter.
Locking torques (N*m)
Tappet cover screws 6 - 7 Nm
TIMING SYSTEM COMPONENTS ASSEMBLY
Name
Tappet cover screws
Spark plug
Tensioner cover
Tensioner screws
Limiting bell screw
Counterweight screw
Plate screws
ENG - 144
Torque in Nm
6 - 7 Nm
12 ÷ 14
5 ÷ 6 Nm
11 ÷ 13
11 ÷ 15 Nm
7 ÷ 8.5
4 ÷ 6 Nm
Beverly Tourer 125
Name
Slider screw
Engine
Torque in Nm
10 ÷ 14 Nm
Refitting the rocker-arms cover
- Refit the cylinder head cover, tightening the 5
clamping screws to the prescribed torque.
- Make sure the gasket is positioned properly.
Locking torques (N*m)
Tappet cover screws 6 - 7 Nm
Refitting the intake manifold
Fit the intake manifold and do up the three screws.
N.B.
FOR SPECIAL SCREWS USE COMMERCIALLY AVAILABLE INSERTS AND INSERT HOLDERS.
Crankcase - crankshaft
Splitting the crankcase halves
First remove the following units:
transmission cover, driving pulley, driven pulley and belt, rear hub cover, gears, bearings and oil seals
as described in the transmission chapter.
- Remove the oil sump, the by-pass, the chain compartment cover and the oil pump as in the lubrication chapter.
- Remove the flywheel cover together with the water pump, the flywheel and the stator as described in
the magneto flywheel chapter.
- Remove the oil filter and the oil pressure switch.
- Remove the cylinder/piston/head unit as described in the cylinder head timing system chapter.
- Remove the two retainers indicated in the figure and the starter motor.
ENG - 145
Engine
Before opening the engine crankcase, it is advisable to check axial clearance of the crankshaft. To
do this, use a plate and a support with appropriate
tool dial gauge.
Higher clearances are signs of wear on the supporting surfaces of the crankshaft casing.
Standard clearance: 0.15 ÷ 0.40 mm
Remove the 11 coupling screws to the crankcase.
- Separate the crankcase while keeping the crankshaft in one of the two halves of the crankcase.
Remove the crankshaft.
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 coupling gasket of the crankcase
halves.
- Remove the two screws and the internal cover
shown in the diagram.
CAUTION
WHILE OPENING THE CRANKCASES AND REMOVING
THE DRIVING SHAFT, CHECK THAT THE THREADED
SHAFT ENDS DO NOT INTERFERE WITH THE MAIN BUSHINGS. FAILURE TO OBSERVE THIS PRECAUTION CAN
DAMAGE THE MAIN BUSHINGS.
- Remove the oil guard on the flywheel side.
- Remove the oil filter fitting shown in the diagram
ENG - 146
Beverly Tourer 125
Beverly Tourer 125
Engine
Fitting clearance
Connecting rod axial clearance 0.20 - 0.50
Check the radial clearance on the connecting rod.
Standard clearance: 0.036 ÷ 0.054 mm
-Check the surfaces that limit the axial free-play
are not scored and measure the width of the crankshaft between these surfaces, as shown in the
diagram.
Standard dimensions:
55.75 ÷ 55.90 mm
N.B.
WHEN MEASURING THE WIDTH OF THE CRANKSHAFT,
MAKE SURE THAT THE MEASUREMENTS ARE NOT
MODIFIED BY THE RADIUSES OF FITTINGS WITH THE
CRANKSHAFT BEARINGS.
If the axial clearance between crankshaft and crankcase exceeds the standard and the crankshaft does
not have any defect, the problem must be due to either excessive wear or wrong machining on the
engine crankcase.
Check the diameters of both bearings of the crankshaft according to the axes and surfaces shown in
the figure. The half-shafts are classified in two categories Cat. 1 and Cat. 2 as shown the chart
below.
Characteristic
Standard diameter - Category 2
29.004 ÷ 29.010
Standard diameter - Category 1
28.994 ÷ 29.000
ENG - 147
Engine
Beverly Tourer 125
The crankshaft can be reused when the width is within the standard values and the surfaces show no
signs of scoring.
Inspecting the crankshaft alignment
To install the drive shaft on the support and to
measure the misalignment in the 4 points indicated
in figure.
- Check that the driving shaft cone, the tab seat,
the oil seal capacity, the toothed gear and the
threaded tangs are in good working order.
- In case of failures, replace the crankshaft.
The connecting rod head bushings cannot be replaced. For the same reason, the connecting rod
may not be replaced and, when cleaning the
crankshaft, be very careful that no impurities get in
through the shaft's lubrication holes.
In order to prevent damaging the connecting rod
bushings, do not attempt cleaning the lubrication
duct with compressed air.
- Make sure that the 2 caps on the crankpin are
properly fitted.
- A wrong installation of a cap can seriously affect
the bushing lubrication pressure.
N.B.
THE MAIN BEARINGS ARE NOT GRINDABLE
Specific tooling
020074Y Support base for checking crankshaft
alignment
Characteristic
Off-line maximum admitted
A = 0.15 mm
B = 0.01 mm
C = 0.01 mm
D = 0.10 mm
ENG - 148
Beverly Tourer 125
Engine
Inspecting the crankcase halves
- Before proceeding to check the crankcase
halves, thoroughly clean all surfaces and oil ducts.
- On the transmission-side crankcase half, take
particular care when handling the oil pump compartment and the oil ducts, the by-pass duct, the
main bushings and the cooling jet on the transmission side (see diagram).
- Take particular care, also, that there are no signs
wear in the oil by-pass valve housing (see Chapter
Lubrication), as this could prevent a good seal in
the valve, which regulates the oil pressure.
- On the flywheel side crankcase half, take particular care cleaning the oil ducts for the main bushings, the oil duct for the jet that lubricates the
cylinder head and the oil drainage duct at the flywheel side oil seal.
- Inspect the coupling surfaces on the crankcase
halves for scratches or deformation, taking particular care with the cylinder/crankcase surfaces and
the crankcase halves surfaces.
- Defects in the crankcase coupling gasket between the crankcase halves or the mating surfaces
shown in the diagram, could cause a drop in the
oil pressure lubricating the main bearings and connection rod.
- Check the main bearing seats that limit axial
clearance in the crankshaft show no signs of wear.
The dimension between these seats is measured
by way of the procedure described previously for
measuring the crankshaft axial clearance and dimensions.
N.B.
THE JET IS FED THROUGH THE MAIN BUSHINGS. PROPER OPERATION OF THIS COMPONENT IMPROVES THE
PISTON TOP COOLING. CLOGGING HAS EFFECTS THAT
ARE DIFFICULT TO DETECT (PISTON TEMPERATURE INCREASE). FAILURE OR LEAK CAN CONSIDERABLY DECREASE THE MAIN BUSHING AND CONNECTING ROD
LUBRICATION PRESSURE.
N.B.
ENG - 149
Engine
THE HEAD LUBRICATION CHANNEL IS PROVIDED WITH
A SHUTTER JET; THIS GIVES A "LOW PRESSURE" HEAD
LUBRICATION; THIS CHOICE WAS MADE TO REDUCE
THE OIL TEMPERATURE IN THE SUMP. THE JET CLOGGING IMPAIRS THE HEAD LUBRICATION AND THE TIMING MECHANISMS. A JET FAILURE CAUSES A DECREASE OF THE MAIN BUSHING AND CONNECTING ROD
LUBRICATION PRESSURE.
Inspecting the crankshaft plain bearings
-T
o obtain a good bushing lubrication it is necessary
to have both an optimal lubricating pressure (3,2
bar) and a good oil flow rate; the bushings must be
correctly positioned so as not to obstruct the oil
supply channels.
- The main bushings are comprised of two halfbearings, one with holes and channels for lubrication whereas the other is solid.
- The solid half-bearing is intended to stand the
thrusts caused by combustion, and for this reason
it is arranged opposite the cylinder.
- To prevent obstructions in the oil feeding channels, the matching surface of the two half-bearings
must be perfectly perpendicular to the cylinder axis, as shown in the figure.
- The oil feeding channel section is also affected
by the bushings driving depth compared with the
crankshaft axial clearance of the limiting surface.
- Check the inside diameter of the main bushings
in the three directions indicated in the diagram.
- Repeat the measurements for the other bushing
half. see diagram.
- There are three crankcase versions: with RED
main bushings, with BLUE main bushings and with
YELLOW main bushings.
- There is only one type of main bushing housing
hole in the crankcase
The standard bushing diameter after driving is variable on the basis of a coupling selection.
ENG - 150
Beverly Tourer 125
Beverly Tourer 125
Engine
- The bushing housings in the crankcase are available in two categories, Cat. 1 and Cat. 2, as are
the crankshafts.
- The main bushings are available in three thickness categories, identified by colour markings, as
shown in the table below.
TYPE
IDENTIFICATION
A
RED
B
BLUE
C
YELLOW
Type "A" -
Type "B" -
Type "C" -
RED
BLUE
YELLOW
Crankshaft
1.970 ÷
1.9703 ÷
1.976 ÷
half-bearing
1.973
1.976
1.979
Bushing
Crankcase
Internal bushing
Possible fit-
category
halves cat-
diameter after fit-
ting
egory
ting
A
1
29.025 ÷ 29.040
Original
B
1
29.019 ÷ 29.034
Original and
2
29.028 ÷ 29.043
spare
2
29.022 ÷ 29.037
Original
C
Match the shaft with two category 1 crank webs
with the category 1 crankcase (or cat. 2 with cat.
2) Furthermore a spare crankcase cannot be
matched with a crankshaft with mixed categories.
The spare crankshaft has half shafts of the same
category.
Crankcase halves
Engine half
Bushing
shaft
Cat. 1
Cat. 1
B
Cat. 2
Cat. 2
B
Cat. 1
Cat. 2
A
Cat. 2
Cat. 1
C
N.B.
TO KEEP THIS POSITION OF THE BUSHINGS ON THE
CRANKCASE, FITTING IS FORCED ON STEEL RINGS INSERTED IN THE CASTING OF BOTH CRANKCASE
HALVES.
N.B.
DO NOT TAKE THE MEASUREMENT ON THE TWO HALFSHELL COUPLING SURFACE SINCE THE ENDS ARE RE-
ENG - 151
Engine
LIEVED TO ALLOW BENDING DURING THE DRIVING
OPERATION.
N.B.
CRANKCASES FOR REPLACEMENTS ARE SELECTED
WITH CRANKCASE HALVES OF THE SAME CATEGORY
AND ARE FITTED WITH CATEGORY B BUSHINGS (BLUE)
Characteristic
Standard driving depth
1.35 ÷ 1.6
Diameter of crankcase without bushing
32.953 ÷ 32.963
Refitting the crankcase halves
- Fit the internal bulkhead by locking the two
screws to the prescribed torque.
- Fit the oil filter fitting and tighten it to the specified
torque.
- Place a new gasket on one of the crankcase
halves, preferably on the transmission side, together with the locating dowels.
- Lubricate the main bushings and insert the crankshaft in the transmission side crankcase half.
- Reassemble the two crankcase halves.
- Fit the 10 screws and tighten them to the prescribed torque.
- Fit a new O-ring on the pre-filter and lubricate it.
- Insert the filter on the engine with the relative cap.
Tighten to the prescribed torque.
Locking torques (N*m)
Internal engine crankcase bulkhead (transmission-side half shaft) screws 4 ÷ 6 Engine-crankcase coupling screws 11 ÷ 13 Oil filter on
crankcase fitting 27 ÷ 33 Engine oil drainage
plug/mesh filter 24 ÷ 30
ENG - 152
Beverly Tourer 125
Beverly Tourer 125
Engine
Lubrication
Conceptual diagrams
LUBRICATION CIRCUIT
ENG - 153
Engine
ENG - 154
Beverly Tourer 125
Beverly Tourer 125
Engine
Oil pressure check
- After removing the flywheel cover as described
in the "Flywheel" chapter, remove the electric connexion of the minimum oil pressure switch and
then remove the switch.
- With the engine idling at 1650 rpm and the oil
temperature at ~90°C, check that the oil pressure
is between 0.5 ÷ 1.2 atm.
- With the engine idling at 6000 rpm and the oil
temperature at ~90°C, check that the oil pressure
is between 3.2 ÷ 4.2 atm.
- Remove the appropriate tools once the measurement is complete, refit the oil pressure switch
and washer, tightening it to the specified torque
and fit the fan 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 GOOD
CONDITION.
Characteristic
Oil pressure
Minimum pressure admitted at 6000 rpm: 3.2 atm.
Locking torques (N*m)
Minimum oil pressure sensor 12 ÷ 14
ENG - 155
Engine
Crankshaft oil seals
Removal
- First remove the transmission cover and the complete driving pulley
- Install the base of the appropriate tool on the oil
guard using the screws provided.
Specific tooling
020622Y Transmission-side oil guard punch
- Screw the threaded bar onto the base of the tool
and extract the oil guard.
Specific tooling
020622Y Transmission-side oil guard punch
Refitting
- Use a new oil seal upon refitting.
- Prepare the new oil seal, lubricating the sealing
lip.
- Preassemble the oil seal with the specific tool,
positioning the screws.
- Place the sheath over the crankshaft.
- Insert the tool with the oil seal on the crankshaft
until it comes into contact with the crankcase.
ENG - 156
Beverly Tourer 125
Beverly Tourer 125
Engine
- Orientate the oil seal by inserting the bracket
which is part of the specific tool.
- Tighten the threaded bar onto the crankshaft as
far as it will go.
- Use the nut to move the base of the tool until you
can feel the end of the oil seal driving stroke.
- Remove all of the tool components following the
inverse procedure
CAUTION
DO NOT LUBRICATE THE SURFACE FOR KEYING ONTO
THE ENGINE CRANKCASE.
CAUTION
ORIENT THE OIL GUARD BY POSITIONING THE CHAIN
HOUSING CHANNEL FACING DOWNWARDS. WHEN THE
POSITION IS REACHED, DO NOT RETRACT THE OIL
GUARD. FAILURE TO COMPLY WITH THIS RULE CAN
CAUSE A WRONG POSITIONING OF THE OIL GUARD
SHEATH.
CAUTION
FAILURE TO COMPLY WITH THIS ASSEMBLY PROCEDURE CAN SERIOUSLY DAMAGE THE ENGINE DUE TO
THE WRONG TENSIONING OF THE OIL PUMP CONTROL
CHAIN.
Specific tooling
020622Y Transmission-side oil guard punch
ENG - 157
Engine
For 125 models, fit a new oil seal on the flywheel
side using the specific tool as shown in the photograph
N.B.
FAILURE TO USE THE SPECIFIC TOOL CAN RESULT IN
AN INCORRECT DEPTH POSITION AND AS A CONSEQUENCE IN INADEQUATE OIL SEALING.
Specific tooling
020425Y Punch for flywheel-side oil seal
Oil pump
Removal
- Undo the two clamping screws in the figure and
remove the cover over the pump control crown.
- Block the rotation of the oil pump control pulley
with a screwdriver inserted through one of its two
holes.
- Remove the central screw with Belleville washer,
as shown in the diagram.
- Remove the chain with the crown.
- Remove the control sprocket with relative O-ring.
ENG - 158
Beverly Tourer 125
Beverly Tourer 125
Engine
- Remove the oil pump by undoing the two screws
in the figure.
- Remove the oil pump seal.
N.B.
IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO ENSURE THAT THE INITIAL DIRECTION OF ROTATION IS
MAINTAINED.
Inspection
- Remove the two screws and the oil pump cover.
- Remove the clip retaining the innermost rotor.
- Remove and wash the rotors thoroughly with petrol and compressed air.
- Reassemble the rotors in the pump body, keeping the two reference marks visible Replace the
snap ring.
- Check the clearance between the rotors in the
position shown in the diagram using a thickness
gauge.
Measure the distance between the outer rotor and
the pump body (see figure).
- Check the axial clearance of the rotors using a
trued bar as shown in the figure.
Characteristic
Axial rotor clearance
Limit values admitted: 0.09 mm
Distance between the outer rotor and the pump
body
Admissible limit clearance: 0.20 mm
Distance between the rotors
Admissible limit clearance: 0.12 mm
ENG - 159
Engine
Refitting
- Check there are no signs of wear on the oil pump
shaft or body.
- Check there are no signs of scoring or wear on
the oil pump cover.
- If you detect non-conforming measurements or
scoring, replace the faulty parts or the unit.
- Fit the pump cover in the position that permits the
crankcase fixing screws to be aligned.
- Make sure the gasket is positioned properly and
refit the pump on the engine crankcase. The pump
can only be fitted in one position. - Tighten the
screws to the prescribed torque.
- Fit the sprocket wheel with a new O-ring.
- Fit the chain.
- Fit the central screw and the belleville washer.
Tighten to the prescribed torque.
- Fit the oil pump cover by tightening the two
screws to the prescribed torque.
N.B.
FIT THE BELLEVILLE WASHER SO THAT ITS OUTER RIM
TOUCHES THE PULLEY. MAKE SURE THAT THE PUMP
TURNS FREELY.
Locking torques (N*m)
Screws fixing oil pump to crankcase 5 - 6 Oil
pump control crown screw 10 ÷ 14 Oil pump cover screws 0.7 ÷ 0.9
ENG - 160
Beverly Tourer 125
Beverly Tourer 125
Engine
Removing the oil sump
- Remove the oil filler plug, the transmission cover,
the complete driving pulley assembly with belt and
the sprocket wheel, as described in the "Transmission" chapter.
- Drain the oil as described previously.
- Remove the seven screws, shown in the diagram, and the two rear brake fluid pipe fixing
brackets.
- Remove the screw, the by-pass piston, the gasket and centring dowels shown in the figure.
Inspecting the by-pass valve
- Check the unloaded spring length.
- Check that the small piston is not scored.
- Ensure that it slides freely on the crankcase and
that it guarantees a good seal.
- If not, eliminate any impurities or replace defective parts.
Characteristic
By-pass check up: Standard length
54.2 mm
ENG - 161
Engine
Refitting the oil sump
- Refit the by-pass valve plunger in its housing.
- Insert the pressure-regulating spring.
- Fit a new sump seal.
- Refit the two centring dowels.
- Refit the sump, taking care to locate the spring in
the appropriate recess machined into the inside of
the sump.
- Refit the rear brake cable brackets and the
screws in the reverse order from which they were
removed.
- Tighten the screws to the prescribed torque.
- Refit the drive pulley assembly, the drive belt, the
sprocket wheel and the transmission cover, as described in the "Transmissions" chapter.
- When testing the lubrication system, refer to
chapter "Crankcase and Crankshaft", regarding lubrication of the crankshaft and connecting rod
Locking torques (N*m)
Oil sump screws 10 ÷ 14
SAS valve
Inspecting the one-way valve
- Remove the SAS valve.
- Provisionally assemble the rubber coupling of the
SAS valve outlet to ensure tightness.
- Connect the MITYVAC vacuum pump to the rubber coupling as shown in the photograph.
- Set the pump to the low-pressure position (VACUUM).
- Operate the pump slowly.
- Check that the one way valve allows the air to
pass through causing a slight vibration.
ENG - 162
Beverly Tourer 125
Beverly Tourer 125
Engine
- Switch the pump to pressure mode (PRESSURE).
- Operate the pump slowly and check if there is an
increase of pressure. A small leakage is considered to be normal.
If anomalies are detected, replace the pump.
N.B.
A MALFUNCTIONING ONE-WAY VALVE CAN RESULT IN
RUBBER COUPLING AND FILTER OVERHEATING
N.B.
ABSENCE OF VIBRATION INDICATES INEFFICIENT SEALING
Specific tooling
020329Y MityVac vacuum-operated pump
Inspecting the cut-off
- Remove the SAS valve.
- Connect the MITYVAC pump in low-pressure
mode (VACUUM) to the CUT-OFF valve vacuum
intake.
- Apply a vacuum value higher than 0.5 BAR.
- Check that this value is kept all the time.
- If a worn seal is detected, replace it.
- With a "T" bypass and flexible rubber hoses make
a parallel connection between the rubber coupling
and the vacuum intake of the CUT-OFF valve.
- Connect the bypass to the MITYVAC pump.
- Set the pump set to the low-pressure mode
(VACUUM).
- Using a pair of long flat pliers, choke the rubber
hose next to the valve.
- Operate the pump until vacuum is higher than 0.5
BAR.
- Release the hose and check how the vacuum reacts. - Under normal functioning conditions the
vacuum undergoes a slight fall and then readjusts.
There follows a slow and continuous loss of depression up to approximately 0.4 BAR. At this point
ENG - 163
Engine
the valve opens and the depression is suddenly
set to zero.
Lack of tightness or the fact that the valve opens
at different vacuum values should be regarded as
anomalies. In this case, replace it.
N.B.
LACK OF TIGHTNESS IN THE CUT-OFF VALVE RESULTS
IN EXHAUST NOISE (EXPLOSIONS IN THE MUFFLER). INCORRECT CUT-OFF VALVE CALIBRATION CAN RESULT
IN CATALYTIC CONVERTER MALFUNCTIONING
N.B.
A FAULTY CUT-OFF VALVE DIAPHRAGM, BESIDES
JEOPARDISING THE CORRECT OPERATION OF THE
CUT-OFF VALVE, ALSO DAMAGES IDLE FUNCTIONING
Specific tooling
020329Y MityVac vacuum-operated pump
Fuel supply
Removing the carburettor
Kehin
- To detach the carburettor from the engine, it is
necessary to move the air filter and remove the
transmission throttle control, the automatic starter
connection, the clamps anchoring the carburettor
to the filter housing and to the inlet manifold, the
air delivery pipe to the diaphragm, and the intake
fitting.
- Take out the carburettor and rotate it so as to
remove the screw with the water joint and the
pipes.
N.B.
THIS LAST OPERATION IS NECESSARY SO AS NO TO
EMPTY THE COOLING SYSTEM.
ENG - 164
Beverly Tourer 125
Beverly Tourer 125
Engine
- Remove the protection, the bracket and the starter acting on the screw shown in the figure.
- Remove the 2 screws and the starter support with
the gasket.
- Remove the clamp and cover with the airing filter
of the diaphragm chamber.
- Remove the 4 fixing screws shown in the figure
and the vacuum chamber cover.
WARNING
DURING THE REMOVAL OF THE CARBURETTOR COVER
TAKE SPECIAL CARE NOT TO RELEASE THE SPRING
ACCIDENTALLY.
ENG - 165
Engine
- Remove the vacuum valve together with the diaphragm.
- Unscrew the bayonet joint 1/8 of a turn and remove, take out the spring and vacuum valve needle
- Remove the 4 screws indicated in the figure.
ENG - 166
Beverly Tourer 125
Beverly Tourer 125
Engine
- Remove the chamber with the accelerating
pump, its control and gasket.
- Remove the oil pump seal.
- Remove the intake and outlet valves of the intake
pump from the tank
N.B.
CAUTION, THE ACCELERATION PUMP VALVES ARE
MADE UP OF NOZZLES, SPRING AND BALL.
N.B.
AVOID REMOVING THE PISTON OF THE PUMP AND ITS
CONTROL.
Adequately support the carburettor and using a
rod and hammer remove the float pin acting from
the throttle control side.
- Remove the float and the plunger.
- Remove the maximum nozzle
ENG - 167
Engine
-Remove the maximum nozzle.
-Remove diffuser.
ENG - 168
Beverly Tourer 125
Beverly Tourer 125
Engine
- Remove the sprayer.
N.B.
WHEN CLEANING THE CARBURETTOR BODY REMOVE
THE SPRAYER TO AVOID LOSING PARTS. IF THE SPRAYER IS FORCED IN ITS HOUSING DO NOT ATTEMPT TO
REMOVE IT AS THIS WILL ONLY DAMAGE IT.
-Remove the minimum nozzle.
- Remove the minimum flow set screw and the
spring.
CAUTION
DO NOT ATTEMPT REMOVING PARTS EMBEDDED IN THE
CARBURETTOR BODY SUCH AS: FUEL SUPPLY PIPE,
PLUNGER HOUSING, STARTER NOZZLE, PIT COVER FOR
PROGRESSIONS AND INLET NOZZLE, MINIMUM AND
MAXIMUM AIR GAUGE, THROTTLE VALVE CONTROL
SHAFT. DO NOT REMOVE THROTTLE-SHAFT CONNECTION SCREWS. THE FIXING SCREWS ARE CAULKED AFTER ASSEMBLY AND THEIR REMOVAL DAMAGES THE
SHAFT.
Refitting the carburettor
ENG - 169
Engine
Beverly Tourer 125
Kehin
- Before refitting, wash the carburettor body accurately with petrol and compressed air.
- Pay special attention to the fuel supply pipe and
the plunger seat.
- For maximum circuit, check the air adjustment is
correct as shown in the figure.
- For the minimum circuit, make sure the following
points are properly cleaned: air gauging, outlet
section controlled by flow screw, progression
holes near the throttle valve.
- For the starter circuit, blow the connection pipe properly with the jet. This is necessary because the
nozzle support hides other inaccessible internal calibrations.
- Blow the intake nozzle properly.
N.B.
THE ACCELERATION NOZZLE OUTLET IS EXTREMELY SMALL AND IS ORIENTED TO THE
THROTTLE VALVE. NOZZLE INCORRECT ORIENTATION RESULTS IN INADEQUATE SPRAYING.
- Check that there are 5 closing ball joints for the operating pipes on the carburettor body.
ENG - 170
Beverly Tourer 125
Engine
- Check that the coupling surfaces, the tank and the diaphragm are not dented.
-Check that the depression valve housing pipe is not scratched.
- Check that the throttle valve and the shaft do not show abnormal wear.
- Check that the plunger seat does not show abnormal wear.
- Replace the carburettor in case of irregularities.
- Check that the return spring of the accelerating pump rocking lever is not deformed by over-stretching.
N.B.
TO AVOID DAMAGES, DO NOT INTRODUCE METAL OBJECTS IN THE ADJUSTED SECTIONS.
- Wash and blow the minimum nozzle properly and
reassemble it.
- Properly wash and blow the components of the
sprayer maximum circuit, the diffuser and the nozzle.
- Introduce the sprayer in the carburettor body with
the shortest cylindrical part directed to the diffuser.
- Assemble the diffuser making sure the sprayer is
being adequately inserted and lock it.
-Assemble the maximum nozzle.
- Check that the tapered pin does not show signs
of wear on the sealing surfaces of the shock absorber pin and the return clamp.
- Replace the rod if worn out.
- Check that the float is not worn on the pin housing or on the contact plate with the plunger and that
there are no fuel infiltration.
- Replace it in case of anomalies.
ENG - 171
Beverly Tourer 125
Engine
- Introduce the float with the rod on the fuel feeding tube side.
N.B.
INTRODUCE THE RETURN SPRING ON THE FLOAT PLATE ADEQUATELY
- Remove the drainage screw from the tank, wash
and blow it properly and make sure the acceleration pump pipes are clean.
- Operate the acceleration pump piston repeatedly
and blow with compressed air.
- Reassemble the acceleration pump valves following this order:
INTAKE VALVE (A)
•
Spring
•
Ball
•
Nozzle
IN VALVE (M)
•
Ball
•
Spring
•
Nozzle
N.B.
THE IN VALVE NOZZLE, CORRESPONDING TO THE ACCELERATION PUMP, IS MILLED.
-Check the screw tightness introducing a small
amount of fuel in the tank.
- Assemble a new gasket on the tank.
- Assemble the tank on the carburettor body fastening the 4 screws.
- Check that the control roller is free to rotate in its
own seat.
N.B.
MAKE SURE THE TANK GASKET IS CORRECTLY INTRODUCED
N.B.
AVOID DEFORMING THE ACCELERATION PUMP CONTROL ROCKING LEVER.
- Wash and blow the flow screw properly.
- Check that screw is not deformed and/or rusty.
- Assemble the spring on the screw.
- Screw the flow screw on the carburettor body.
ENG - 172
Beverly Tourer 125
Engine
- The screw final position should be determined by an exhaust fume analysis.
- Adjust the carburettor by turning the screw twice from the close position.
Level check
Kehin
- Place the carburettor inclined as shown in the
figure.
- Check that the float reference is parallel to the tank coupling surface
- If different positions are detected, change the plunger control metal plate direction to obtain the position
described above.
Inspecting the valve and needle
Kehin
- Check that the tapered pin of the vacuum valve
does not show wear.
- Check that the depression valve does not show
threads on the external surfaces.
- Check that the vacuum intake hole is not clogged.
- Check that the diaphragm is not damaged or has
hardened, otherwise replacement the whole valve.
- Insert the tapered pin into the vacuum valve
housing.
- Reassemble the vacuum valve on the carburettor
body taking care that the tapered pin is inserted
into the sprayer.
N.B.
THE VALVE CAN BE INSERTED IN ONLY ONE POSSIBLE
POSITION.
ENG - 173
Engine
- Reassemble the spring with the pin lock.
- Remove the cover of the vacuum chamber being
careful to correctly insert the spring in its place on
the cover.
- Tighten the screws.
- Wash and blow dry the filter sponge of the ambient pressure intake.
ENG - 174
Beverly Tourer 125
Beverly Tourer 125
Engine
- Reassemble the filter with its clamp.
- Wash and blow dry the starter support.
Assemble a new gasket on the carburettor body
and tighten the 2 fixing screws.
Inspecting the automatic choke device
Kehin
- Check that the automatic starter piston is not deformed or rusty.
- Check that the piston slides freely from the seat
to the support.
- Check that the piston sealing gasket is not deformed.
- The starter must be more or less functional depending on the ambient temperature.
- Measure the protrusion of the piston as shown in
the figure and check its corresponding value.
- Make sure that the starter is adjusted for the ambient temperature.
- The starter should disconnect progressively by
means of electric heating.
ENG - 175
Engine
- Check the starter resistance when adjusted to the
ambient temperature.
With a 12V battery power the automatic starter and
check that the piston protrudes as much as possible.
- The correct warm up time depends on the ambient temperature.
- If protrusion, resistance or timing values are different from the ones prescribed, replace the starter.
- Assemble the starter to the carburettor being
careful to position the O-Ring correctly, insert the
plate with the machined side contacting the starter,
tighten the fixing screws.
- Position the starter as shown in the figure.
- Assemble the protection casing.
N.B.
TO CARRY OUT THIS CHECK PAY SPECIAL ATTENTION
NOT TO GENERATE SHORT CIRCUITS USE A CABLE
SECTION WITH A TERMINAL SUITABLE TO BE CONNECTED TO THE STARTER.
Characteristic
Protrusion value
10 mm at about 24°
Starter resistance
20 Ω
Check the automatic starter: Keihin maximum
time
5 min
ENG - 176
Beverly Tourer 125
INDEX OF TOPICS
SUSPENSIONS
SUSP
Suspensions
Beverly Tourer 125
Front
Removing the front wheel
- Remove the front calliper.
- Loosen the wheel axle lock-nut.
- Loosen the two wheel axle safety screws on the fork leg, on the brake calliper side.
- Pull out the wheel axle.
See also
Removal
Front wheel hub overhaul
Check that the wheel bearings do not show signs
of wear.
If you have to replace the wheel bearings, proceed
as follows:
- Remove the plastic cover on the tone wheel side
to avoid damage by loosening the 5 fixing screws.
- Remove the two bearings on the odometer drive
side using the pliers 14 or 34 and the bell detail 9.
- Remove the internal spacer.
SUSP - 178
Beverly Tourer 125
Suspensions
* Either tool can be used.
- Support the front wheel with two wooden shims
that make it possible to avoid scratching in the
case of contact with the rim.
- Insert the punch (consisting of adaptor handle,
15 mm adaptor and guide) from the odometer drive
side to permit the removal of the brake disc side
bearing and the spacer bushing.
Specific tooling
020376Y Adaptor handle
020456Y Ø 24 mm adaptor
020412Y 15 mm guide
- Heat the bearing seat on the side the brake disc
with the heat gun.
- Insert the bearing using the punch consisting of
adaptor handle, 42x47 mm adaptor and 15 mm
guide, and drive it up to the stop.
SUSP - 179
Suspensions
- Reinsert the spacer bushing on the brake disc
side using the appropriate tool and take it to the
stop.
Specific tooling
020376Y Adaptor handle
020359Y 42x47-mm adaptor
020412Y 15 mm guide
020201Y Spacer bushing driving tube
- Turn over the wheel and insert the internal spacer
with the part fitted with the Seeger ring facing the
bearing on the brake disc side installed previously.
- Heat the bearing seat on the odometer drive side
with the heat gun.
- Insert the two bearings using the punch consisting of adaptor handle, 32x35 mm adaptor and 15
mm guide, and drive it up to the stop.
Specific tooling
020376Y Adaptor handle
020357Y 32 x 35 mm adaptor
020412Y 15 mm guide
SUSP - 180
Beverly Tourer 125
Beverly Tourer 125
Suspensions
- Refit the cap and tighten the five fixing screws.
Refitting the front wheel
- Grease the wheel axle, then install it from the
tone wheel side and install the tone wheel properly.
- Tighten the wheel axle nut to the prescribed torque.
N.B.
TAKE CARE NOT TO DAMAGE THE ODOMETER DRIVE.
FOR THE SAKE OF SAFETY, OFFSET THE INTERNAL
STOP FROM THE STOP OF THE TONE WHEEL BY 90°.
- Tighten the two safety screw on the leg to the
prescribed torque.
Locking torques (N*m)
Front wheel axle nut 45 - 50 Safety screw on fork
leg 6 ÷ 7
Handlebar
SUSP - 181
Suspensions
Removal
- Remove the rear handlebar cover.
- Remove the pin mounting the handlebar to the
steering tube.
- Remove the handlebar and place it on the rear
cover of the front shield.
See also
Rear handlebar cover
Refitting
- Install the handlebars on the steering tube, paying attention to the centring, aligning the recess on
the handlebar with that on the steering tube as
shown in the figure.
- Tighten the handlebar fixing screw on the steering tube to the prescribed torque.
Locking torques (N*m)
Handlebar fixing screw 45 ÷ 50
Front fork
Removal
Overhaul
- Support the fork in a vice.
- Loosen the two tightening screws of the stem
supporting clamp.
- Unscrew the stem closing cap and slide off the
complete fork leg from the corresponding support.
CAUTION
THE STEM CLOSING CAP KEEPS THE MAIN SPRING PRELOADED. KEEP THE CAP PROPERLY FITTED DURING
THE REMOVAL FINAL STAGE TO AVOID ACCIDENTS.
SUSP - 182
Beverly Tourer 125
Beverly Tourer 125
Suspensions
- Support the fork leg properly, remove the main
spring and drain off the fork leg oil.
- Remove the hydraulic rod fixing screw with the
corresponding sealing gasket:
- With a 19-mm hexagonal spanner, lock hydraulic
rod rotation.
- Undo the fixing screw and collect the copper
washer.
- Remove the stem dust guard with a screwdriver.
SUSP - 183
Suspensions
Beverly Tourer 125
- Remove the circlip retaining the oil seal.
- Take out the stem.
- Check there are no signs of wear or seizing between the stem and the fork leg. Otherwise, replace
the damaged parts.
Characteristic
Maximum leg diameter
35.10 mm
Minimum stem diameter
34.90 mm
- Take out the oil seal using the appropriate tools.
- Fit the tie rod into the oil seal.
- Insert in sequence the two half-rings per Ø 35mm stems.
Specific tooling
020487Y Fork oil seal extractor
SUSP - 184
Beverly Tourer 125
Suspensions
- Hold the tie rod manually so that it does not fall
into the fork leg and/or that both half-rings are not
in their position.
- Fit the bell.
- Tighten the nut until it stops.
- Act on the tool until the oil seal is completely removed.
Specific tooling
020487Y Fork oil seal extractor
- Remove the hydraulic rod with the corresponding
sealing gasket, the spring and the stop bushing.
COMPONENT CHECK
CAUTION
CLEAN ALL THE COMPONENTS THOROUGHLY.
- Check that the fork leg is not cracked or broken
in the attachments.
- Check that the stem is not scored, dented or distorted.
- Check that the stop bushing for the hydraulic rod
is correctly fixed through caulking.
SUSP - 185
Suspensions
- Check that hydraulic rod caulkings, the return
spring to the unloaded the end of stroke and the
hydraulic rod sealing ring are in good conditions.
- Check that the main spring exhibits no signs of
yielding or abnormal wear.
- Check that the closing cap O-ring of the stem is
in good conditions.
SUSP - 186
Beverly Tourer 125
Beverly Tourer 125
Suspensions
Refitting
- First grease the splitting chamber of the two sealing lips of a new oil seal.
- Fit the sealing ring on the stem and keep the
identification words facing upwards.
- Drive the oil seal as far as it will go using the appropriate tool.
Specific tooling
020376Y Adaptor handle
020359Y 42x47-mm adaptor
- Pre-fit the stem with the hydraulic rod, the spring
and the stop bushing.
- Fit the pre-assembled components inside the fork
leg.
- Fit the hydraulic rod fixing screw with the copper
sealing washer and tighten to the prescribed torque using the recommended product.
CAUTION
ALWAYS USE NEW COPPER WASHER.
Locking torques (N*m)
Hydraulic rod fixing screw 25 ÷ 35*
(°) Apply LOCTITE 243 threadlock
- Lock hydraulic rod rotation using a 19-mm hexagonal spanner.
SUSP - 187
Suspensions
- Fit the oil seal retaining circlip.
- Grease and fit a new dust guard.
- Fit the fork leg together with the stem on the fork
supporting clamp until it stops.
- Tighten the two screws to the prescribed torque
in the sequence indicated in the photograph.
Locking torques (N*m)
Stem support clamp tightening screws 20 ÷ 25
- Refill the fork leg with the recommended product
to the prescribed amount.
Recommended products
AGIP FORK 7.5 W Oil for front fork
Hydraulic fluid SAE 7.5 W
Characteristic
Oil quantity per stem
133 ± 3 cm³
SUSP - 188
Beverly Tourer 125
Beverly Tourer 125
Suspensions
- Bleed the hydraulic rod by actuating the stem repeatedly.
- Fit the spring into the stem.
- Lubricate the closing cap O-ring of the stem.
- Preload the spring, fit the closing cap and tighten
to the prescribed torque.
Locking torques (N*m)
Fork locking screws cap 15 ÷ 30
- Repeat the procedure for the other fork leg.
N.B.
IF BOTH FORK LEGS ARE SERVICED AT THE SAME TIME, BE CAREFUL NOT TO INVERT THE
RIGHT FORK LEG WITH THE LEFT ONE.
Steering column
SUSP - 189
Suspensions
Removal
- Remove the front wheel.
- Remove the front mudguard
- Remove the front brake calliper
- Remove the front and rear handlebar covers.
- Remove the pin mounting the handlebar to the
steering tube.
- Remove the handlebar and rest it on the shield
back plate.
- Remove by releasing the cable passages and
sliding the protection collar upwards.
Using the special tool, loosen and remove the upper ring nut, the spacer washer and the counterring nut.
- Extract the fork.
N.B.
TAKE CARE TO SUPPORT THE FORK SO AS TO PREVENT
IT FROM COMING OFF ABRUPTLY
Specific tooling
020055Y Wrench for steering tube ring nut
Refitting
- Fit the lower steering fifth wheel on the steering
tube.
- Fit the fork together with the lower steering fifth
wheel on the headstock and hold it so that it does
not fall.
N.B.
LUBRICATE THE STEERING FIFTH WHEEL TRACKS WITH
RECOMMENDED GREASE BEFORE USE.
Recommended products
AGIP GREASE PV2 Grease for steering bearings, bolt seatings for swinging arms and faySUSP - 190
Beverly Tourer 125
Beverly Tourer 125
Suspensions
ing surface of driven pulley spring (only pulley
side)
Soap-based lithium and zinc oxide grease containing NLGI 2; ISO-L-XBCIB2
- Fit the upper steering fifth wheel.
CAUTION
INSERT THE UPPER FIFTH WHEEL WITH THE CAGE FACING UPWARDS.
- Fit the steering fifth wheel upper seat.
- Fit the cover plate.
SUSP - 191
Suspensions
- Insert the lower tightening ring nut, screw until it
stops and, with the specific tool, tighten to the prescribed torque.
Specific tooling
020055Y Wrench for steering tube ring nut
Locking torques (N*m)
Steering tube lower ring nut 14 ÷ 17
- Fit the spacer between the two ring nuts on the
steering tube in the position indicated.
- Insert the upper tightening ring nut, screw until it
stops and, with the specific tool, tighten to the indicated torque.
Specific tooling
020055Y Wrench for steering tube ring nut
Locking torques (N*m)
Steering tube upper ring nut 40 ÷ 45
SUSP - 192
Beverly Tourer 125
Beverly Tourer 125
Suspensions
Insert the collar shown in the figure and restore the
cable passage as shown in the figure.
- Fit the front wheel.
Steering bearing
Removal
- Clean thoroughly and visually inspect if the components are in good conditions.
- Check the upper steering fifth wheel for wear.
SUSP - 193
Suspensions
- Check the lower steering fifth wheel for wear.
- Visually inspect that the steering fifth wheel
tracks, the headstock and the steering tube exhibit
no scores or abnormal wear. Otherwise, replace
them.
STEERING FIFTH WHEEL TRACK REMOVAL
- Remove the steering fifth wheel tracks on the
chassis with the specific tool, following the indicated procedure.
- Fit the specific tool from the lower part of the
headstock until it makes contact with the upper
track.
- Hit with force the specific tool, placing it at different points diametrically opposed so as to remove
the upper track.
Specific tooling
020004Y Punch for removing fifth wheels from
headstock
SUSP - 194
Beverly Tourer 125
Beverly Tourer 125
Suspensions
- Repeat the procedure for the lower steering fifth wheel track.
- Remove the lower fifth wheel seat on the steering
tube using the specific tool.
Specific tooling
020004Y Punch for removing fifth wheels from
headstock
SUSP - 195
Suspensions
Refitting
STEERING FIFTH WHEEL TRACK FITTING
- Thoroughly clean the track seats on the headstock and the steering tube.
- Fit the new tracks of the headstock with the specific tool.
- Screw the nut until the tracks are fully inserted.
N.B.
LUBRICATE THE STEERING FIFTH WHEEL TRACKS WITH
RECOMMENDED GREASE BEFORE USE.
Specific tooling
001330Y Tool for fitting steering seats
001330Y014 Tool for fitting steering seats
001330Y015 Tool for fitting steering seats
Recommended products
AGIP GREASE PV2 Grease for steering bearings, bolt seatings for swinging arms and faying surface of driven pulley spring (only pulley
side)
Soap-based lithium and zinc oxide grease containing NLGI 2; ISO-L-XBCIB2
- Fit the lower fifth wheel seat on the steering tube.
- With a tube of the indicated sizes, fit the lower
seat until it stops. Inside Ø: 35.5 mm; Outside Ø:
38 mm; Length: 350 mm.
N.B.
LUBRICATE THE STEERING FIFTH WHEEL TRACKS WITH
RECOMMENDED GREASE BEFORE USE.
Recommended products
AGIP GREASE PV2 Grease for steering bearings, bolt seatings for swinging arms and faying surface of driven pulley spring (only pulley
side)
SUSP - 196
Beverly Tourer 125
Beverly Tourer 125
Suspensions
Soap-based lithium and zinc oxide grease containing NLGI 2; ISO-L-XBCIB2
Rear
Removing the rear wheel
- Remove the muffler support bracket
- Remove the 5 screws shown in the photograph
Refitting the rear wheel
- Carry out the removal operations but in reverse order, observing the prescribed tightening torques.
Locking torques (N*m)
Fixing screw for wheel rim to hub 34 ÷ 38
Swing-arm
Removal
- Place the scooter on its centre stand;
- Support the engine adequately;
- Loosen the nut shown in the figure and pull out
the spindle from the left-hand side.
SUSP - 197
Suspensions
- Loosen the nut and lock nut on the left-hand side
of the scooter (see figure) and unscrew the spindle
from the opposite side.
- Remove the retaining screw of the rear brake
pipe shown in the figure.
- Loosen the nut on the inside of the frame from
the left-hand side (see figure) and remove the relevant spindle;
- Remove the swinging arm.
Overhaul
- Check that the silent bloc is not damaged. If there
is, replace it.
- Remove the Seeger ring shown in the photograph
- Remove the full silent bloc bracket
- Hold the full silent bloc bracket in the clamp
- Using the appropriate tool, remove the silent bloc
from the bracket from the side corresponding to
the inside of the vehicle. This is to guarantee the
tool is centred properly on the support
Specific tooling
020271Y Tool for removing-fitting silent bloc
SUSP - 198
Beverly Tourer 125
Beverly Tourer 125
Suspensions
- Install a new silent bloc, making sure it aligns
properly with the reference tooth.
- Fit the silent blocs, making sure the chamfered
part of the silent bloc matches the chamfered part
of the bracket
- Using the appropriate tool, fit the silent bloc as
shown in the photo
Specific tooling
020271Y Tool for removing-fitting silent bloc
- Check there is no sticking in the movement of the
connection of the swinging arm on the engine side
to the swinging arm on the frame side.
- Check the axial clearance between the two
swinging arms using a feeler gauge
Characteristic
Allowable limit after use:
1 mm
standard clearance
0.40 ÷ 0.70 mm
SUSP - 199
Suspensions
- In order to check the clearance of the swinging
arm on the frame side, prepare a retainer using the
fixing pin of the swinging arm on the frame and two
rings from the special tool 020229Y.
Alternatively, use two washers with inside diameter of 12 mm for pins, outside diameter min. 30 mm
and thickness min. 4 mm.
- Separate the swinging arm on the engine side
from the vehicle side arm.
- Remove the internal spacer shown in the photograph
- Using a suitable pin remove the roller casings as
shown in the photographs
SUSP - 200
Beverly Tourer 125
Beverly Tourer 125
Suspensions
- Using an appropriate tool plant new roller casings, being careful to position the bearings with the
O-rings facing outwards
Specific tooling
020115Y Ø 18 punch
020244Y 15 mm diameter punch
SWINGING ARM SERVICE
Specification
Length of the internal swinging arm spacer on the frame side
Length of the internal swinging arm spacer on the engine side
Length of the swinging arm tube on the engine side
Length of the swinging arm tube on the frame side
Desc./Quantity
228 -0.2/-0.4 mm
183 0/-0.2 mm
182.5 -0.1/-0.3 mm
227.1+0.2/0 mm
- Lubricate the roller bearing housings with grease
- Insert the spacers
- Assemble the two arms with the relative bolt in
the position shown in the photograph
- Adjust the bolt as shown in the photograph
- Position the frame side swinging arm with the
most protruding part pointing towards the silent
block side as shown in the photograph
Recommended products
AGIP GREASE PV2 Grease for control levers
on the engine
White anhydrous-calcium based grease to protect
roller bearings; temperature range between -20 °
C and +120 °C; NLGI 2; ISO-L-XBCIB2
Refitting
For correct installation of the swinging arm on the
scooter, proceed as follows:
1. Position the silent block supporting clamp with
part 3 inserted, and slightly tighten part 1
2. Position the swinging arm, inserting part 2
3. Tighten part 3 to the prescribed torque
4. Screw on and tighten part 4 to the prescribed
torque
SUSP - 201
Beverly Tourer 125
Suspensions
5. Screw on and tighten part 5 to the prescribed
torque
6. Tighten part 1 to the prescribed torque
Insert the swinging arm - engine bolt and tighten
to the prescribed torque
SWINGING ARM FITTING
Name
Part 1
Part 3
Part 4
Part 5
Engine-swinging arm bolt
SUSP - 202
Torque in Nm
64 ÷ 72 Nm
5 - 7 Nm
90 ÷ 110 Nm
64 ÷ 72 Nm
64 - 72
Beverly Tourer 125
Suspensions
Shock absorbers
Removal
Proceed as follows:
- place the scooter on its centre stand;
- lift the engine a little with a jack so as to free the
two shock absorbers;
- remove the muffler
- undo the shock absorber spring assembly clamping screw from the support fixed to the engine on
the one side and from that fixed to the muffler on
the other;
- unscrew the two upper nuts (one on each side)
fixing the shock absorber spring assembly to the
frame and remove the shock absorbers.
See also
Exhaust assy. Removal
Refitting
Carry out the previous operations but in reverse order.
Locking torques (N*m)
Lower shock absorber clamp 33 ÷ 41 Upper shock absorber clamp 33 ÷ 41
Exhaust bracket
SUSP - 203
Suspensions
Removal
- Remove the exhaust silencer.
- Loosen and remove the lower retaining bolt of the
right-hand shock absorber at the support arm.
- Undo the two screws fixing the arm to the engine.
- Remove the split pin and safety cover; unscrew
the wheel axle nut; use the rear brake to prevent
the wheel from turning.
- Remove the support arm.
Overhaul
- Remove the circlip shown in the photograph
- Support the muffler support bracket sufficiently
- Using the special punch, remove the bearing
from its seat as shown in the photograph
Specific tooling
020376Y Adaptor handle
020456Y Ø 24 mm adaptor
- Heat the bearing seat using the heat gun
- Using the special punch, install a new bearing in
the seat as shown in the photograph
Specific tooling
020376Y Adaptor handle
020151Y Air heater
SUSP - 204
Beverly Tourer 125
Beverly Tourer 125
Suspensions
Refitting
To refit, carry out the removal operations in reverse order, observing the prescribed tightening torques.
Locking torques (N*m)
Rear wheel axle nut 104 ÷ 126 Muffler support arm to engine screws (*) 20 ÷ 25 Lower shock
absorber clamp 33 ÷ 41
Centre-stand
- Remove the two return springs from the centre
stand.
- Undo the nut shown in the figure.
- Remove the bolt from the right side.
- Remove the centre stand.
- On refitting tighten the nut to the specified torque.
Locking torques (N*m)
Centre stand bolt 32 ÷ 40
Side stand
Removal of the side stand
- Unhook the springs;
- Loosen the nut;
- Pull out the screw;
Fitting
Carry out the previous operations but in reverse
order.
Locking torques (N*m)
Side stand fixing bolt 40 ÷ 45
SUSP - 205
INDEX OF TOPICS
BRAKING SYSTEM
BRAK SYS
Beverly Tourer 125
Braking system
Interventions rules
WARNING
BRAKING SYSTEM FLUID IS CORROSIVE: ALWAYS WEAR PROTECTIVE GLOVES. IN THE
EVENT OF ACCIDENTAL CONTACT WITH YOUR EYES, RINSE THE CONTACT AREA WELL
WITH ABUNDANT WATER.
THE BRAKE FLUID DRAINED FROM THE SYSTEM IS HARMFUL TO THE ENVIRONMENT. COLLECTION AND DISPOSAL MUST BE CARRIED OUT IN COMPLIANCE WITH THE REGULATIONS
IN FORCE. UNDER NORMAL DRIVING AND CLIMATIC CONDITIONS YOU SHOULD CHANGE
THE FLUID EVERY TWO YEARS. IF BRAKES ARE USED INTENSELY AND/OR IN HARSH CONDITIONS, CHANGE THE FLUID MORE FREQUENTLY.
DURING INSTALLATION, THE PARTS TO BE REUSED MUST BE ABSOLUTELY CLEAN AND
FREE FROM ANY TRACES OF OIL, FUEL AND GREASE: IT IS THEREFORE NECESSARY TO
CLEAN THEM THOROUGH WITH DENATURED ALCOHOL.
N.B.
FOR TOPPING UP AND CHANGE, USE ONLY BRAKE FLUID DOT4 - NHTSA 116.
OBSERVE THE MAXIMUM DEGREE OF CLEANLINESS. HYDRAULIC FLUID IS EXTREMELY
CORROSIVE FOR PAINTED SURFACES.
BRAKE FLUID IS HYGROSCOPIC; THAT IS, IT ABSORBS MOISTURE FROM THE SURROUNDING AIR.
IF THE MOISTURE CONTENT IN THE BRAKE FLUID EXCEEDS A CERTAIN VALUE, IT WILL RESULT IN POOR BRAKING EFFICIENCY DUE TO A LOW BOILING POINT OF THE FLUID.
N.B.
ALWAYS USE FLUID FROM SEALED CONTAINERS.
N.B.
RUBBER PARTS SHOULD NEVER BE LEFT IN ALCOHOL LONGER THAN 20 SECONDS. AFTER
WASHING, THE PIECES MUST BE DRIED WITH A BLAST OF COMPRESSED AIR AND A CLEAN
CLOTH.
THE SEAL RINGS MUST BE IMMERSED IN THE OPERATING FLUID; THE USE OF PRF1 PROTECTIVE DEVICE IS ALLOWED.
WARNING
THE PRESENCE OF BRAKE FLUID ON THE DISC OR BRAKE PADS REDUCES BRAKING EFFICIENCY. IN THIS CASE, REPLACE THE PADS AND CLEAN THE DISC WITH A HIGH-QUALITY
SOLVENT.
Rear brake calliper
Removal
- Remove the rear wheel.
- Remove the two rear brake calliper devices fastening them to the support as shown in the photograph.
N.B.
SHOULD THE BRAKE CALLIPER BE REPLACED, BEFORE
REMOVING THE FITTINGS FIXING THE CALLIPER TO THE
SUPPORTING BRACKET, FIRST LOOSEN THE OIL HOSE
FITTING AFTER HAVING EMPTIED THE SYSTEM OF THE
CIRCUIT BEING INSPECTED.
BRAK SYS - 207
Braking system
Beverly Tourer 125
Refitting
- Follow the removal procedures but in reverse order and tighten to the prescribed torques with the
recommended product.
Recommended products
Loctite 243 Medium strength threadlock
Loctite 243 medium-strength threadlock
Locking torques (N*m)
Screw tightening calliper to the support 42 ÷ 52
If the calliper is replaced:
CAUTION
ONCE REFITTING IS FINISHED, BLEED THE SYSTEM.
CAUTION
ALWAYS USE NEW COPPER WASHERS.
Locking torques (N*m)
Pipe - brake calliper union 20 ÷ 25
See also
Rear - combined
Front brake calliper
Removal
- Remove the two retainers fastening the front
brake calliper to the support as shown in the photograph.
N.B.
SHOULD IT BE NECESSARY TO REPLACE THE CALLIPER, FIRST LOOSEN THE FITTING CONNECTING THE PIPE
TO THE BRAKE CALLIPER.
Refitting
- To fit the calliper, follow the above operations but in reverse order.
Locking torques (N*m)
Screw tightening calliper to the support 20 ÷ 25
If the calliper is replaced:
CAUTION
ONCE REFITTING IS FINISHED, BLEED THE SYSTEM.
CAUTION
ALWAYS USE NEW COPPER WASHERS.
BRAK SYS - 208
Beverly Tourer 125
Braking system
Locking torques (N*m)
Pipe - brake calliper union 20 ÷ 25
See also
Front
Rear brake disc
Sui veicoli può essere presente la ruota posteriore con mozzo integrato oppure quella con mozzo separato dalla ruota.
Removal
RUOTA POSTERIORE CON MOZZO SEPARATO
- Remove the rear wheel.
- Act on the disc five fixing screws shown in the
photograph.
See also
Removing the rear wheel
Refitting
RUOTA POSTERIORE CON MOZZO SEPARATO
- For the installation, position the disc correctly using the arrow stamped on it as reference.
- Tighten the screws to the prescribed torque and
apply the recommended product.
N.B.
THE SURFACE OF THE DISC WITH THE STAMPED ARROW FOR THE DIRECTION OF ROTATION MUST FACE
TOWARDS THE OUTSIDE OF THE SCOOTER.
Recommended products
Loctite 243 Medium strength threadlock
Loctite 243 medium-strength threadlock
Locking torques (N*m)
Brake disc fixing screws 11 ÷ 13
BRAK SYS - 209
Braking system
Beverly Tourer 125
Disc Inspection
Checking the disc is important; it must be perfectly
clean, with no sign of rust, oil or grease or any other dirt, and must show no signs of deep scoring.
Characteristic
New rear disc thickness
4.0 mm
Disc thickness at wear limit (rear)
3.5 mm
- Controllare mediante attrezzatura apposita, che
lo scostamento assiale della superficie frenante
rientri nei parametri prescritti.
- In caso contrario sostituire il disco e rifare la prova.
WHEN INSTALLING, THOROUGHLY CLEAN THE DISC
AND ITS SEAT ON THE HUB.
Characteristic
Max. axial run-out
0.1 mm
Front brake disc
Removal
Proceed as follows:
- Remove the front wheel.
- Loosen the five disc fixing screws.
- Thoroughly clean the seats on the front wheel
hub and on the disc.
See also
Removing the front wheel
Refitting
For fitting, position the disc correctly using the arrow stamped on it as reference.
- Do up the screws to the prescribed torque and apply the recommended product
BRAK SYS - 210
Beverly Tourer 125
Braking system
N.B.
THE ARROW STAMPED ON THE DISC INDICATING THE RUNNING DIRECTION MUST BE FITTED
TOWARDS THE OUTSIDE OF THE VEHICLE.
Recommended products
Loctite 243 Medium strength threadlock
Loctite 243 medium-strength threadlock
Locking torques (N*m)
Brake disc screws 8 ÷ 10
Disc Inspection
Checking the disc is important; it must be perfectly
clean, with no sign of rust, oil or grease or any other dirt, and must show no signs of deep scoring.
Characteristic
Thickness of a new front disc
4.0 mm
Disc thickness at wear limit (front)
3.5 mm
- Remove the wheel and check using the appropriate tools that the axial run-out of the brake
surface is within the prescribed limits.
- If this is not the case, replace the disc and repeat
the test.
WHEN INSTALLING, THOROUGHLY CLEAN THE DISC
AND ITS SEAT ON THE HUB.
Characteristic
Max. axial run-out
0.1 mm
Front brake pads
BRAK SYS - 211
Braking system
Beverly Tourer 125
Removal
Proceed as follows:
- Remove the front calliper.
- Loosen the two pins shown in the figure that lock
the two pads.
- Remove the pads, being careful with the pad
spring clamp.
- Check the thickness of the friction material of the
pads.
- Replace the pads if the thickness is below the
minimum value.
- The replacement must be made with greater residual thickness if the pad has not worn evenly. A
0.5 mm thickness difference in the residual friction
material is permitted.
Characteristic
Minimum value
1.5 mm
See also
Front
brake calliper
Refitting
To fit, proceed as follows:
- Insert the two pads in the callipers.
- Screw the two pad lock pins to the correct torque, and apply the recommended product.
- Fit the calliper on its support, tightening the two screws to the prescribed torque.
N.B.
IF IT IS NOT POSSIBLE TO CORRECTLY POSITION THE CALLIPER ON THE DISC DURING FITTING, GENTLY EXPAND THE PADS.
Recommended products
Loctite 243 Medium strength threadlock
BRAK SYS - 212
Beverly Tourer 125
Braking system
Loctite 243 medium-strength threadlock
Locking torques (N*m)
Pad fastening pin 19.6 ÷ 24.5
Rear brake pads
Removal
- Remove the rear brake calliper
- Loosen the two pins shown in the figure that lock
the two pads; be careful with the pad spring clamp.
- Remove the brake pad and check there are no
faults or warping. Replace it if such anomalies are
present.
- Check the thickness of the friction material is
more than 1.5 mm. If it is not , replace it
- The replacement must be made with greater residual thickness if the pad has not worn evenly. A
0.5 mm thickness difference in the residual friction
material is permitted.
See also
Removal
BRAK SYS - 213
Braking system
Beverly Tourer 125
Refitting
To fit, proceed as follows:
- Insert the two pads in the callipers.
- Screw the two pad lock pins to the correct torque,
and apply the recommended product.
- Fit the calliper on its support, tightening the two
screws to the prescribed torque.
N.B.
IF IT IS NOT POSSIBLE TO CORRECTLY POSITION THE
CALLIPER ON THE DISC DURING FITTING, GENTLY EXPAND THE PADS.
Recommended products
Loctite 243 Medium strength threadlock
Loctite 243 medium-strength threadlock
Locking torques (N*m)
Pad fastening pin 19.6 ÷ 24.5
Fill
Rear - combined
- Remove the rubber hood from the bleed screw.
- Insert a rubber pipe in the bleed screw to permit
the brake fluid to be recovered.
- With the brake lever, load the system and bring
it up to the required pressure.
- Keeping the brake lever pulled, loosen the bleed
screw to purge the air in the system. Then tighten
the bleed screw
- Repeat the operation until only brake fluid comes out of the rubber pipe.
- Remove the fluid recovery pipe and refit the rubber cap over the bleed screw.
- Top up the brake fluid to the right level in the reservoir.
If necessary, bleeding can be done using a special vacuum pump
N.B.
DURING THE BLEEDING OPERATIONS, MAKE SURE THE BRAKE FLUID DOES NOT COME INTO
CONTACT WITH THE BODYWORK SO AS NOT TO DAMAGE IT. FURTHERMORE, DURING THE
BLEEDING OPERATIONS REGARDING THE BRAKE CALLIPERS, MAKE SURE THE BRAKE
FLUID DOES NOT COME INTO CONTACT WITH THE DISC BRAKES AND WITH THE BRAKE
PADS. FAILURE TO COMPLY WITH THIS NORM WILL ENDANGER THE PROPER WORKING AND
EFFICIENCY OF THE BRAKING SYSTEM
Specific tooling
BRAK SYS - 214
Beverly Tourer 125
Braking system
020329Y MityVac vacuum-operated pump
Locking torques (N*m)
Oil bleed screw 12 - 16
Front
- Remove the rubber hood from the bleed screw.
- Insert a rubber pipe in the bleed screw to permit
the brake fluid to be recovered.
- With the brake lever, load the system and bring
it up to the required pressure.
- Keeping the brake lever pulled, loosen the bleed
screw to purge the air in the system. Then tighten
the bleed screw
- Repeat the operation until only brake fluid comes out of the rubber pipe.
- Remove the fluid recovery pipe and refit the rubber cap over the bleed screw.
- Top up the brake fluid to the right level in the reservoir.
If necessary, bleeding can be done using a special vacuum pump
N.B.
DURING THE BLEEDING OPERATIONS, MAKE SURE THE BRAKE FLUID DOES NOT COME INTO
CONTACT WITH THE BODYWORK SO AS NOT TO DAMAGE IT. FURTHERMORE, DURING THE
BLEEDING OPERATIONS REGARDING THE BRAKE CALLIPERS, MAKE SURE THE BRAKE
FLUID DOES NOT COME INTO CONTACT WITH THE DISC BRAKES AND WITH THE BRAKE
PADS. FAILURE TO COMPLY WITH THIS NORM WILL ENDANGER THE PROPER WORKING AND
EFFICIENCY OF THE BRAKING SYSTEM
Specific tooling
020329Y MityVac vacuum-operated pump
Locking torques (N*m)
Oil bleed screw 12 - 16
Brake fluid level check
The front and rear brake fluid reservoirs are both
positioned on the handlebars. 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.
BRAK SYS - 215
Braking system
Beverly Tourer 125
Front brake pump
Removal
- Remove the rear handlebar cover.
- Drain the brake system.
- Disconnect the brake fluid line from the pump,
paying attention to a possible escape of remaining
brake fluid.
- Remove the brake stop button from the lever.
- Undo the two U-bolt fixing screws.
- Remove the brake pump with the lever.
Refitting
- Upon refitting, perform the operation but in reverse order.
- Tighten the hydraulic line to the prescribed torque and purge the system.
- When the operation is over, tighten the brake fluid bleed screw to the prescribed torque.
N.B.
WHILE REFITTING, REPLACE THE COPPER GASKETS ON THEIR FITTINGS.
WARNING
BRAKE FLUID IS HYGROSCOPIC; THAT IS, IT ABSORBS MOISTURE FROM THE SURROUNDING AIR. IF THE LEVEL OF MOISTURE IN THE FLUID EXCEEDS A GIVEN VALUE, BRAKING WILL
BE INEFFICIENT. THEREFORE, ALWAYS USE FLUID FROM SEALED CONTAINERS. UNDER
NORMAL DRIVING AND CLIMATIC CONDITIONS YOU SHOULD CHANGE THIS FLUID EVERY
TWO YEARS. IF BRAKES ARE USED INTENSELY AND/OR IN HARSH CONDITIONS, CHANGE
THE FLUID MORE FREQUENTLY.
CAUTION
WHEN CARRYING OUT THE OPERATION, BRAKE FLUID MAY LEAK FROM BETWEEN THE
BLEED SCREW AND ITS SEAT ON THE CALLIPER. CAREFULLY DRY THE CALLIPER AND DEGREASE THE DISC SHOULD THERE BE BRAKE FLUID ON IT.
Locking torques (N*m)
Oil bleed screw 12 - 16 Hydraulic line fixing screw: 16 ÷ 20 Fixing screws for handlebar control
assembly U-bolts 7 ÷ 10
See also
Front
Rear brake pump - combined
BRAK SYS - 216
Beverly Tourer 125
Braking system
Removal
- Remove the rear handlebar cover.
- Drain the brake system.
- Disconnect the brake fluid line from the pump,
paying attention to a possible escape of remaining
brake fluid.
- Remove the brake stop button from the lever.
- Undo the two U-bolt fixing screws.
- Remove the brake pump with the lever.
Refitting
- Upon refitting, perform the operation but in reverse order.
- Tighten the hydraulic line to the prescribed torque and purge the system.
- When the operation is over, tighten the brake fluid bleed screw to the prescribed torque.
N.B.
WHILE REFITTING, REPLACE THE COPPER GASKETS ON THEIR FITTINGS.
WARNING
BRAKE FLUID IS HYGROSCOPIC; THAT IS, IT ABSORBS MOISTURE FROM THE SURROUNDING AIR. IF THE LEVEL OF MOISTURE IN THE FLUID EXCEEDS A GIVEN VALUE, BRAKING WILL
BE INEFFICIENT. THEREFORE, ALWAYS USE FLUID FROM SEALED CONTAINERS. UNDER
NORMAL DRIVING AND CLIMATIC CONDITIONS YOU SHOULD CHANGE THIS FLUID EVERY
TWO YEARS. IF BRAKES ARE USED INTENSELY AND/OR IN HARSH CONDITIONS, CHANGE
THE FLUID MORE FREQUENTLY.
CAUTION
WHEN CARRYING OUT THE OPERATION, BRAKE FLUID MAY LEAK FROM BETWEEN THE
BLEED SCREW AND ITS SEAT ON THE CALLIPER. CAREFULLY DRY THE CALLIPER AND DEGREASE THE DISC SHOULD THERE BE BRAKE FLUID ON IT.
Locking torques (N*m)
Oil bleed screw 12 - 16 Hydraulic line fixing screw: 16 ÷ 20 Fixing screws for handlebar control
assembly U-bolts 7 ÷ 10
See also
Rear - combined
BRAK SYS - 217
INDEX OF TOPICS
COOLING SYSTEM
COOL SYS
Beverly Tourer 125
Cooling system
Circuit diagram
COOLING CIRCUIT
Specification
A
B
Desc./Quantity
Fluid cooling circuit
Thermostat with By-Pass
COOL SYS - 219
Beverly Tourer 125
Cooling system
Specification
C
D
E
Desc./Quantity
Expansion tank
Radiator
Carburettor heating circuit
Electric fan check
- To check electric fan activation, with the key switch set to «ON», jump the Green-Black electrical
terminals of the thermoswitch.
Thermoswitch operation check:
- Remove the front shield.
- Remove the thermoswitch «1».
- Connect a tester «2» (set as ohmmeter) to the
thermoswitch «1» as shown in the figure.
- Immerse the thermoswitch in a container «3» with
coolant.
In the same container, immerse a thermometer
«4» with a temperature range of 0°÷150° (32°
÷302°F).
- Place the container on a stove «5» and warm up
the coolant slowly.
- Check that the temperature indicated on the thermometer and the thermoswitch value indicated on
the tester correspond to the data on the table.
COOLANT TEMPERATURE °C (°F) / RESISTANCE VALUES (OHM)
Specification
Less than 90° (194°)
More than 90° (194°)
System bleed
- Start up the engine until the operating temperature is reached.
- Remove the rubber hood over the bleed valve
- Obtain a rubber tube that is of the right length to
connect the valve to the expansion tank
- Place one end of the pipe on the bleed valve and
the other in the expansion tank
- Loosen the screw by two turns until the communication hole is revealed with the head as shown
in the photo
COOL SYS - 220
Desc./Quantity
Unlimited
0
Beverly Tourer 125
Cooling system
- Wait until only coolant comes out of the rubber
pipe so as to eliminate any air bubbles inside the
circuit.
- Tighten the bleed valve respecting the maximum
torque.
- Bring the coolant up to the correct level inside the
expansion tank
Locking torques (N*m)
Bleed screw 3
COOL SYS - 221
INDEX OF TOPICS
CHASSIS
CHAS
Beverly Tourer 125
Chassis
Seat
- Remove the saddle by loosening the three retaining screws indicated in the figure;
Side fairings
- Remove side bumpers by removing the mounting
screws shown in the figure (one on each side).
Rear rack
- Loosen the two mounting screws and remove the
battery cover.
Remove the plastic cover of the rear luggage rack
by removing the two side screws from the lower
side of the rack.
- Loosen the 3 hexagonal retaining screws indicated in the figure and remove luggage rack.
CHAS - 223
Chassis
Rear handlebar cover
- Remove the windshield.
- Remove the rear-view mirrors.
- On both sides of the handlebar undo the screw
indicated and remove the brake pump compartment inspection cover.
- Undo the screw indicated.
- From below undo the screw fixing it to the front
handlebar cover.
- Undo the two screws fixing it to the frame.
- Remove the rear handlebar cover after disconnecting the electrical connectors and the odometer
cable.
CHAS - 224
Beverly Tourer 125
Beverly Tourer 125
Chassis
Instrument panel
- Remove the rear handlebar cover.
- Undo the four screws shown in the photograph.
- Remove the instrument panel.
See also
Rear handlebar cover
Front handlebar cover
- Remove the rear handlebar cover.
- Disconnect the electrical connectors of the headlamp and turn indicators.
- Undo the five screws indicated and remove the
headlight assembly and the front handlebar cover.
- During the fitting stage, make sure that the retainer clamp indicated is placed correctly.
Headlight assy.
CHAS - 225
Chassis
Frame central cover
- Open the fuel tank access port.
- Loosen the 4 screws shown in the figure.
- At the same time, remove the fuel tank cap.
Remove the frame central cover by sliding it from
the rear side of the scooter and disconnecting it
from the cover opening transmission.
Legshield
- Remove the fixing screw of the expansion tank
access cover.
- Unscrew the 2 fixing screws on the upper part of
the shield back plate indicated in the figure.
- Undo the 2 fixing screws to the wheel housing.
CHAS - 226
Beverly Tourer 125
Beverly Tourer 125
Chassis
- Remove the central frame cover, then unscrew
the 2 screws indicated in the figure.
- Remove the Piaggio symbol from the shield, then
remove the screw.
- Remove the legshield to the front.
- To reassemble, follows the steps in reverse order, paying attention to the correct seating of the
shield on the shield back plate.
See also
Headlight assy.
Frame central cover
Knee-guard
- Remove the legshield.
- Undo the two screws fixing the fuse box to the
front glove-box.
- Remove the electrical connections.
- Remove the expansion tank.
- Undo the fixing screw inside the glove-box.
CHAS - 227
Chassis
- Disconnect the saddle closing mechanism.
- Remove the rear shield with the glove box.
See also
Legshield
Removing the ignition key-switch when on *off*
- Remove the shield back plate.
- Remove the immobilizer aerial as shown in the
figure.
- Detach the electrical wiring.
- Remove the ignition key-switch, by removing the
spring retainer shown in the figure.
- Lightly push the master-cylinder and extract the
lock from the notch shown in the figure.
- Hence extract the master-cylinder complete with
the key-switch.
- To refit, proceed in the reverse order.
See also
CHAS - 228
Beverly Tourer 125
Beverly Tourer 125
Chassis
Knee-guard
Removing the ignition key-switch when on *lock*
In position "Lock", it is not possible to access the
cylinder retaining spring. The spring must then be
removed as shown in the figure, allowing the lock
spring to be pressed out.
N.B.
TO REFIT THIS ITEM, THE SCOOTER STEERING LOCK
MUST BE RELEASED WITH THE LOCK BODY (INTERNAL
AND EXTERNAL PART) IN POSITION "OFF". PROCEED AS
DESCRIBED IN THE PREVIOUS PARAGRAPH.
See also
Removing the ignition key-switch when on *off*
Front wheel housing
- Remove the shield back plate.
- Remove the footrests.
- Remove the front suspension.
- Loosen the remaining retaining screws holding
the central chassis cover.
- Remove the radiator cover.
See also
Knee-guard
Removing the front wheel
Footrest
Taillight assy.
- Remove the cover of the luggage rack (snappedin).
- Remove the side bumpers.
- Unscrew the 3 screws holding the rear light.
- Remove the rear light assembly after disconnecting the electrical cable harness.
See also
CHAS - 229
Chassis
Side fairings
Footrest
- Remove the central cover.
- Remove the RHS footrest mat.
- Loosen the eight footrest mounting screws.
- Remove the RHS footrest.
- Repeat the same operations for the LHS footrest.
See also
Frame central cover
Frame central cover
Side fairings
- Remove the saddle.
- Remove the luggage rack.
- Remove the central cover.
- Remove the rear light assembly.
- Remove the cover under the saddle by loosening
the retaining screw located under the saddle
mounting plate.
- Loosen the 6 side-fairing fixing screws indicated
in the 3 photographs.
- Remove the fairings.
CHAS - 230
Beverly Tourer 125
Beverly Tourer 125
Chassis
See also
Seat
Rear rack
Frame central cover
Taillight assy.
Rear rack
Seat
Taillight assy.
Frame central cover
Air filter
- Undo the two screws indicated.
CHAS - 231
Chassis
- Reach the inspection compartment inside the
helmet compartment.
- Disconnect the two manifold clamps.
- Disconnect the two clamps connecting the blowby tube.
Rear mudguard
- Loosen the 4 fixing screws, 2 of which are indicated in the figure and the other 2 located on the
opposite side under the air filter;
- Remove the rear mudguard.
Helmet bay
- Remove the side fairings; - Disconnect the electrical connections; - Undo the 8 fixing screws, 4 of
which are inside the compartment; - Remove the
license plate holder support by undoing the 4 fixing
screws shown in the figure and disconnecting the
electrical cable harness; - Remove the helmet
compartment.
CHAS - 232
Beverly Tourer 125
Beverly Tourer 125
Chassis
Fuel tank
- Remove the shield back plate.
- Remove the front wheel housing.
- Remove the footrest.
N.B.
THIS OPERATION SHOULD PREFERABLY BE PERFORMED WITH THE TANK EMPTY.
- Separate the electrical connections of the fuel
gauge and disconnect the fuel supply line and tank
breather;
- Undo and remove the screw fixing the horn
shown in the upper figure after disconnecting the
electrical connection;
- Remove the toggle handles by loosening the 4
retaining screws;
- Remove the support bracket by loosening the 2
retaining screws of the bracket at the frame;
- Undo the two screws fixing the tank to the chassis;
- Remove the tank by tilting it downwards and pulling out from below.
See also
Front wheel housing
Knee-guard
Footrest
CHAS - 233
Chassis
Front mudguard
- Remove the retaining screw of the cable lead
through support on the right-hand side of the mudguard. - Loosen the 3 fixing retaining screws indicated in the figure and remove the mudguard.
Radiator fan
- Remove the front wheel housing.
- Prepare a container for the coolant.
- Remove the expansion tank outlet and return
pipes.
- Remove the coolant supply and return pipes from
the radiator.
- Loosen the screw mounting the radiator to the
frame.
- Disengage the radiator and the electric fan.
See also
Front wheel housing
Flyscreen
- Undo the screw indicated.
CHAS - 234
Beverly Tourer 125
Beverly Tourer 125
Chassis
- Undo the four screws indicated and remove the
windshield.
CHAS - 235
INDEX OF TOPICS
PRE-DELIVERY
PRE DE
Beverly Tourer 125
Pre-delivery
Carry out the listed tests before delivering the vehicle.
Warning- be very careful when handling fuel.
Aesthetic inspection
Appearance check:
- Paintwork
- Fitting of plastics
- Scratches
- Dirt
Tightening torques inspection
- Visually check that there is a yellow mark on the following clamps:
FRONT SUSPENSION
•
Front wheel pin nut
•
Screw fixing wheel pin on right fork leg
FRONT BRAKE
•
Screws fixing front brake callipers to fork
•
Brake pipes to front brake callipers couplings
REAR SUSPENSION
•
Rear wheel tightening screws
•
Shock absorber lower clamp
•
Upper shock absorber clamp
•
Swinging arm - engine retainer
•
Swinging arm - chassis retainer
•
Nuts fixing muffler supporting arm - engine
•
Screws fixing muffler to supporting arm
REAR BRAKE
•
Screws fixing rear brake calliper to supporting plate
•
Brake pipe / rear brake calliper coupling
•
Screws fixing the support plate to engine
STAND
•
Central stand bolt nuts
Electrical system
Electrical system:
- Main switch
PRE DE - 237
Pre-delivery
Beverly Tourer 125
- Headlamps: high beam, low beam, position and parking lights and the respective warning lights
- Adjusting the headlights according to the regulations currently in force
- Rear light, parking light, stop light
- Front and rear stop light switches
- Turn indicators and their warning lights
- Instrument panel lights
- Instrument panel: fuel and temperature indicator
- Instrument panel warning lights
- Horn
- Starter
CAUTION
TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE.
INADEQUATE CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFORE
IT IS FIRST USED SHORTENS BATTERY LIFE.
WARNING
BEFORE RECHARGING THE BATTERY, REMOVE THE CAPS OF EACH CELL.
KEEP THE BATTERY AWAY FROM NAKED FLAMES OR SPARKS WHILE IT IS CHARGED.
REMOVE THE BATTERY FROM THE SCOOTER, DISCONNECTING THE NEGATIVE TERMINAL
FIRST.
CAUTION
WHEN INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEGATIVE LEAD.
WARNING
BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SULPHURIC ACID. AVOID CONTACT WITH EYES, SKIN AND CLOTHING.
IN CASE OF CONTACT WITH EYES OR SKIN, RINSE WITH ABUNDANT WATER FOR ABOUT 15
MINUTES AND SEEK MEDICAL ATTENTION AT ONCE.
IF IT IS SWALLOWED, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR VEGETABLE
OIL. SEEK IMMEDIATE MEDICAL ATTENTION.
BATTERIES PRODUCE EXPLOSIVE GAS; KEEP THEM AWAY FROM NAKED FLAMES, SPARKS
AND CIGARETTES. IF THE BATTERY IS CHARGED IN A CLOSED PLACE, TAKE CARE TO ENSURE ADEQUATE VENTILATION. ALWAYS PROTECT YOUR EYES WHEN WORKING CLOSE TO
BATTERIES.
KEEP OUT OF THE REACH OF CHILDREN
CAUTION
NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY. USING
A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE
A FIRE.
Levels check
Level check:
- Hydraulic braking system fluid level.
- Rear hub oil level
- Engine coolant level.
PRE DE - 238
Beverly Tourer 125
Pre-delivery
Road test
Test ride
- Cold start
- Instrument operations
- Response to the throttle control
- Stability on acceleration and braking
- Rear and front brake efficiency
- Rear and front suspension efficiency
- Abnormal noise
Static test
Static control after the test ride:
- Starting when warm
- Starter operation
- Minimum hold (turning the handlebar)
- Uniform turning of the steering
- Possible leaks
CAUTION
CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE.
CAUTION
NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES OR TYRES MAY BURST.
Functional inspection
Functional check up:
Braking system (hydraulic)
- Lever travel
Braking system (mechanical)
- Lever travel
Clutch
- Proper functioning check
Engine
- Throttle travel check
Others
- Check documentation
- Check the frame and engine numbers
- Tool kit
- License plate fitting
- Check locks
PRE DE - 239
Pre-delivery
- Check tyre pressures
- Installation of mirrors and any accessories
PRE DE - 240
Beverly Tourer 125
INDEX OF TOPICS
TIME
TIME
Beverly Tourer 125
Time
Engine
ENGINE
1
Code
001001
2
3
003064
003057
TIME - 242
Action
Engine from frame - Removal and refit.
Engine oil - Change
Engine retainer - Tighten nuts
Duration
Beverly Tourer 125
Time
Crankcase
CRANKCASE
1
Code
001153
2
3
4
001133
001099
001124
Action
Crankcase halves gasket - Replacement
Engine crankcase - Replacement
Oil seal, flywheel side - Replacement
Lubrication by-pass - Replacement
Duration
TIME - 243
Beverly Tourer 125
Time
Crankshaft
CRANKSHAFT
1
TIME - 244
Code
001117
Action
Crankshaft - Replacement
Duration
Beverly Tourer 125
Time
Cylinder assy.
CYLINDER- PISTON
1
2
Code
001002
001154
Action
Cylinder-Piston - Replacement
Pin ring piston unit - Service
Duration
TIME - 245
Beverly Tourer 125
Time
Cylinder head assy.
VALVE HEAD
1
2
3
4
5
6
TIME - 246
Code
001126
001045
001049
001056
001083
001057
Action
Head - Replacement
Valves - Replacement
Valves - Adjustment
Head gasket - Replacement
Thermistor - Replacement
Thermostat - Replacement
Duration
Beverly Tourer 125
Time
Rocker arms support assy.
CAMSHAFT - ROCKING LEVERS
1
2
Code
001148
001044
Action
Valve rocking levers - Replacement
Camshaft - Replacement
Duration
TIME - 247
Beverly Tourer 125
Time
Cylinder head cover
HEAD COVER
1
2
3
4
TIME - 248
Code
001093
001089
001088
001074
Action
Spark plug - Replacement
Head cover - Replacement
Head cover gasket - Replacement
Oil vapour recovery pipe - Replacement
Duration
Beverly Tourer 125
Time
Oil filter
OIL FILTER
1
2
Code
001123
001160
Action
Oil filter - Replacement
Oil pressure sensor - Replacement
Duration
TIME - 249
Beverly Tourer 125
Time
Driven pulley
DRIVEN PULLEY
1
2
3
4
5
TIME - 250
Code
001022
003072
001012
001110
001155
Action
Clutch - Replacement
Clutch unit - Wear check
Driven pulley - Service
Driven pulley - Replacement
Clutch bell housing - Replacement
Duration
Beverly Tourer 125
Time
Oil pump
PUMP - OIL SUMP UNIT
1
2
3
4
5
6
7
8
Code
001125
001051
001042
001112
001122
001121
001130
001129
Action
Chain guide pads - Replacement
Belt/ Timing chain - Replacement
Oil pump - Service
Oil pump - Replacement
Oil pump chain - Replacement
Chain cover oil seal - Replacement
Oil sump - Replacement
Chain tightener - Overhaul and replacement
Duration
TIME - 251
Beverly Tourer 125
Time
Final gear assy.
FINAL REDUCTION
1
2
3
Code
001010
003065
001156
4
004125
TIME - 252
Action
Geared reduction unit - Service
Gear box oil - Replacement
Geared reduction unit cover - Replacement
Rear wheel axle - Replacement
Duration
Beverly Tourer 125
Time
Driving pulley
DRIVING PULLEY
1
2
3
Code
001086
001011
001066
4
5
001006
001141
Action
rear-view half-pulley - Replacement
Driving belt - Replacement
Driving pulley - Removal and Refitting
driving pulley - Service
Belt anti-flapping roller - Replacement
Duration
TIME - 253
Beverly Tourer 125
Time
Transmission cover
TRANSMISSION COVER
1
Code
001135
2
001096
3
001131
TIME - 254
Action
Transmission cover bearing - Replacement
Transmission crankcase cover - replace
Transmission air intake - Replacement
Duration
Beverly Tourer 125
Time
Flywheel magneto
MAGNETO FLYWHEEL AND SECONDARY AIR
1
2
Code
001087
001113
Action
Flywheel cover - Replacement
Water pump / Pump rotor - Replacement
Duration
TIME - 255
Beverly Tourer 125
Time
3
4
5
6
Code
001058
001173
001067
001161
7
001162
8
9
001174
001163
Carburettor
TIME - 256
Action
Flywheel - Replacement
Rotor - Replacement
Stator - Replacement
Secondary air filter - Replacement /
Cleaning
Secondary air housing - Replacement
SAS valve - Replacement
SAS valve / Head connection - Replacement
Duration
Beverly Tourer 125
Time
CARBURETTOR
1
2
3
4
5
Code
001013
001081
001008
001063
007020
6
003058
Action
Intake manifold - Replacement
Automatic choke - Replacement
Carburettor - Inspection
Carburettor - Replacement
Carburettor heating tubing - replacement
Carburettor - Adjustment
Duration
TIME - 257
Beverly Tourer 125
Time
Exhaust pipe
MUFFLER
1
2
3
TIME - 258
Code
001009
001095
001092
Action
Muffler - Replacement
Muffler guard - Replacement
Exhaust manifold - Replacement
Duration
Beverly Tourer 125
Time
Air cleaner
AIR CLEANER
1
2
3
Code
001014
001015
004122
Action
Air filter - Replacement/Cleaning
Air filter box - Replacement
Carburettor air cleaner attachment Replacement
Duration
TIME - 259
Beverly Tourer 125
Time
Frame
CHASSIS
1
TIME - 260
Code
004001
Action
Chassis - Replacement
Duration
Beverly Tourer 125
Time
Centre-stand
CENTRE AND SIDE STANDS
1
2
Code
004004
004102
Action
Stand - Replacement
Side stand - Replacement
Duration
TIME - 261
Beverly Tourer 125
Time
Legshield spoiler
LEGSHIELD - SPOILER
1
TIME - 262
Code
004064
Action
Legshield - Replacement
Duration
Beverly Tourer 125
Time
Side fairings
SIDE COVERS
1
2
Code
004012
004052
Action
Rear side panels - Replacement
Bumper - Replacement
Duration
TIME - 263
Beverly Tourer 125
Time
Footrests
MATS AND COVERS
1
2
Code
004075
004079
3
4
5
004015
004085
004011
TIME - 264
Action
Front mat - Replacement
Passenger footrest (1) - Replacement
Footrests - Remov. and Refit.
Fairing (1) - Replacement
Central chassis cover - Replacement
Duration
Beverly Tourer 125
Time
Rear cover
REAR SHIELD
1
Code
004065
2
004081
Action
Legshield rear section - Remov. and
Refit.
Glove box door - Replacement
Duration
TIME - 265
Beverly Tourer 125
Time
Underseat compartment
HELMET COMPARTMENT- SEAT ELECTRIC OPENING-LICENCE PLATE HOLDER
1
Code
004016
2
3
4
5
004106
005046
004142
005026
TIME - 266
Action
Helmet compartment - Remov. and
Refit.
Underseat band - Replacement
Battery cover - Replacement
Plug socket - Replacement
Helmet compartment light - Replacement
Duration
Beverly Tourer 125
Time
Mudguard
FRONT AND REAR MUDGUARDS
1
2
3
Code
004009
004002
004053
Action
Rear mudguard - Replacement
Front mudguard - Replacement
Spoiler - Replacement
Duration
TIME - 267
Beverly Tourer 125
Time
Fuel tank
FUEL TANK
1
2
3
4
TIME - 268
Code
005010
004109
004005
004007
Action
Tank float - Replacement
Fuel tank breather - Replacement
Fuel tank - Replacement
Fuel valve - Replacement
Duration
Beverly Tourer 125
Time
Rear shock-absorber
REAR SHOCK ABSORBER
1
Code
003007
2
003077
Action
Rear shock absorber - Remov. and
Refit.
Muffler supporting arm/ rear shock
absorber - Replacement
Duration
TIME - 269
Beverly Tourer 125
Time
Steering column bearings
STEERING FIFTH WHEELS
1
2
3
4
Code
003051
003079
003048
004119
5
6
7
8
003002
003073
003010
003050
TIME - 270
Action
Fork unit - Replacement
Fork stem - Replacement
Fork oil seal - Replacement
Bearing/upper steering fifth wheel Replacement
Steering fifth wheel - Replacement
Steering clearance - Adjustment
Front suspension - Service
Fork lower plate - Replacement
Duration
Beverly Tourer 125
Time
Handlebar covers
HANDLEBAR COVERS
1
Code
004018
2
004019
Action
Front handlebar covers - Replacement
Rear handlebar cover - Replacement
Duration
TIME - 271
Beverly Tourer 125
Time
Handlebar components
HANDLEBAR COMPONENTS
1
2
3
4
Code
002060
002037
002071
002024
5
6
7
002067
003001
002063
8
9
002059
003061
TIME - 272
Action
Throttle grip - Replacement
Brake or clutch lever - Replacement
Left knob - Replacement
Front brake pump - Removal and Refitting
Rear brake pump - Replacement
Handlebar - Replacement
Complete throttle grip transmission Replacement
Right-hand knob - Replacement
Accelerator transmission - Adjustment
Duration
Beverly Tourer 125
Time
Swing-arm
SWINGING ARM
1
Code
001072
2
004058
Action
Swinging arm - Engine-chassis connection - Replacement
Silent block - Replacement
Duration
TIME - 273
Beverly Tourer 125
Time
Brake hoses
BRAKE PIPING
1
2
Code
002021
003070
3
4
5
002007
002039
002047
6
002020
7
003071
8
9
002002
002080
10
002048
TIME - 274
Action
Front brake piping - Replacement
Front brake pads/shoes - Check for
wear
Front brake pads - Replacement
Front brake calliper - Replacement
Front brake fluid and air bleeding
system - Replacement
Rear brake disc piping - Replacement
Rear brake pads/shoes - Check for
wear
Rear brake pads - Replacement
Rear brake oil bleeding system - Replacement
Rear brake calliper - Replacement
Duration
Beverly Tourer 125
Time
Seat
SADDLE
1
Code
004003
Action
Saddle - Replacement
Duration
TIME - 275
Beverly Tourer 125
Time
Instrument panel
INSTRUMENT PANEL
1
2
TIME - 276
Code
005014
005038
Action
Odometer - Replacement
Instrument panel warning light bulbs
- Replacement
Duration
Beverly Tourer 125
Time
Rear rack
LUGGAGE RACK
1
Code
004008
Action
Luggage rack - Replacement
Duration
TIME - 277
Beverly Tourer 125
Time
Locks
LOCKS
1
2
3
Code
005016
004010
002083
4
004158
5
005099
6
004054
TIME - 278
Action
Key switch - Replacement
Anti-theft lock - Replacement
Saddle opening transmission - Replacement
Saddle opening splitter - Replacement
Electric saddle opening device - Replacement
Saddle lock catch - Replacement
Duration
Beverly Tourer 125
Time
Turn signal lights
TIME - 279
Beverly Tourer 125
Time
TURN INDICATOR LIGHTS
1
2
3
4
Code
005002
005005
005008
005031
5
005032
6
7
005066
005067
8
005068
TIME - 280
Action
Front headlamp - Replacement
Taillight - Replacement
Headlight bulbs - Replacement
Licence plate light bulb - Replacement
Licence plate light glass - Replacement
Rear light bulbs - Replacement
Front turn indicator light - Replacement
Rear turn indicator bulb - Replacement
Duration
Beverly Tourer 125
Time
Front wheel
FRONT WHEEL
1
2
3
4
5
6
7
Code
003038
002011
003040
003047
003037
002041
004123
Action
Front wheel axle - Replacement
Odometer drive - Replacement
Front wheel bearings - Replacement
Front tyre - replace
Front wheel rim- Replacement
Front brake disc - Replacement
Front wheel - Replacement
Duration
TIME - 281
Beverly Tourer 125
Time
Rear wheel
REAR WHEEL
1
2
3
4
TIME - 282
Code
001016
004126
001071
002070
Action
Rear wheel - Replacement
Rear wheel tyre - Replacement
Rear wheel rim - Replacement
Rear brake disc - Replacement
Duration
Beverly Tourer 125
Time
Electric start
ELECTRICAL START-UP
1
2
Code
001020
001017
Action
Starter motor - Replacement
Start-up pinion - Replacement
Duration
TIME - 283
Beverly Tourer 125
Time
Fuel pump
FUEL PUMP
1
2
Code
004073
004137
3
4
004089
004072
TIME - 284
Action
Fuel pump - Replacement
Carburettor pump hose - Replacement
Tank-pump hose - Replacement
Fuel filter - Replacement
Duration
Beverly Tourer 125
Time
Electric devices
TIME - 285
Beverly Tourer 125
Time
ELECTRIC DEVICES
1
2
3
Code
005007
005009
005011
4
5
6
7
8
001023
001069
001094
005003
005035
1
2
Code
005039
005077
3
005006
4
5
6
005040
005041
005079
Action
Battery - Replacement
Voltage regulator - Replacement
Start-up remote control switch - Replacement
Control unit - Replacement
HV coil - Replacement
Spark plug cap - Replacement
Horn - Replacement
Headlight remote control - Replacement
Duration
ELECTRIC DEVICES
TIME - 286
Action
Headlight switch - Replacement
Emergency stop switch - Replacement
Light switch or turn indicators - Replacement
Horn button - Replacement
Starter button - Replacement
Stand switch - Replacement
Duration
Beverly Tourer 125
Time
ELECTRIC DEVICES
1
2
3
Code
005001
005052
005054
Action
Electrical system - Replacement
Fuse (1) - Replacement
Fuse block (1) - Replacement
Duration
TIME - 287
Beverly Tourer 125
Time
Transmissions
TRANSMISSIONS
1
Code
002051
2
3
002049
002082
TIME - 288
Action
Odometer transmission assembly Replacement
Odometer cable - Replacement
Fuel tank cap opening drive - Replacement
Duration
Beverly Tourer 125
Time
Rear side fairings
REAR COVERS
1
Code
004136
Action
License plate holder support - Replacement
Duration
TIME - 289
Beverly Tourer 125
Time
Cooling system
COOLING SYSTEM
1
Code
007014
2
3
007002
007016
4
007003
5
6
007001
007013
7
001052
TIME - 290
Action
Radiator thermal switch - Replacement
Radiator water - Replacement
Complete fan with support - Replacement
Coolant delivery and return pipe - Replacement
Expansion tank - Replacement
Expansion tank - radiator connection
pipe - Replacement
Coolant and air bleed - Replacement
Duration
Beverly Tourer 125
Time
Secondary air box
SECONDARY AIR HOUSING
1
Code
001163
2
001164
Action
Muffler secondary air connection Replacement
Crankcase secondary air connection
- Replacement
Duration
TIME - 291
A
Air filter: 41, 231
B
Battery: 55, 73, 81, 82
Brake: 207–213, 215, 216, 274
Brake fluid: 215
C
Carburettor: 13, 36, 164, 169, 256
Coolant:
E
Engine oil: 41
Engine stop:
F
Fuel: 54, 164, 233, 268, 284
Fuses: 80
H
Headlight: 48, 225, 227
Horn: 76
Hub oil: 39
I
Identification: 8
Instrument panel: 65, 225, 276
L
Luggage rack:
M
Maintenance: 7, 36
O
Oil filter: 43, 249
S
Saddle:
Shock absorbers: 203
Spark plug: 38, 71
Stand: 205
Start-up:
T
Tank: 233, 268
Transmission: 10, 54, 96, 110, 254
Tyres: 11
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