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SERVICE STATION MANUAL Beverly 125 This service station manual has been drawn up by Piaggio & C. Spa to be used by the workshops of Piaggio-Gilera dealers. This manual is addressed to Piaggio service mechanics who are supposed to have a basic knowledge of mechanics principles and of vehicle repairing techniques and procedures.
INDEX OF TOPICS CHAR HARACTERISTICS TOOL OOLING MAIN AINTENANCE TROUBL ROUBLESHOOTING ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE NGINE SUSP USPENSIONS BRAK SYS RAKING SYSTEM COOL SYS OOLING SYSTEM CHAS HASSIS PRE DE DELIVERY TIME...
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.
Beverly 125 Characteristics Brakes BRAKES Specification Desc./Quantity Front brake Ø 260-mm disc brake with hydraulic control activated by han- dlebar right-side lever. Rear brake Ø 260-mm disc brake with hydraulic control activated by han- dlebar left lever. Wheels and tyres...
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Beverly 125 Characteristics Air is drawn through the opening «A», goes through the first filter and is channelled through the opening «B». 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.
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Beverly 125 Characteristics Carburettor 125cc Version Kehin KEIHIN CARBURETTOR Specification Desc./Quantity Type Depression carburettor Model CVK 30 Body stamping Tapered pin stamping 304D CUT-OFF device Not present Diffuser Ø 29 Maximum jet Minimum jet Max. air jet Minimum air jet Throttle valve spring 100 ÷...
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Beverly 125 Characteristics FRAME ASSEMBLY Name Torque in Nm Engine-swinging arm bolt 64 - 72 Chassis-swinging arm pin nut 64 - 72 Spacer locking threaded bushing 13 ÷ 17 Spacer locking threaded bushing lock nut 90 ÷ 110 Frame arm-engine arm coupling pin nut 33 ÷...
Beverly 125 Characteristics Piston rings ENGINE SEALING RINGS Name Description Dimensions Initials Quantity Compression ring 57 x 1 0.15 ÷ 0.30 Oil scraper ring 57 x 1 0.10 ÷ 0.30 Oil scraper ring 57 x 2.5 0.15 ÷ 0.35 Crankcase - crankshaft - connecting rod...
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Beverly 125 Characteristics CRANKSHAFT/ CRANKCASE AXIAL CLEARANCE Name Description Dimensions Initials Quantity Half-shaft, transmission 16.6 +0-0.05 D = 0.20 - 0.50 side Flywheel-side half-shaft 16.6 +0-0.05 D = 0.20 - 0.50 Connecting rod 18 -0.10 -0.15 D = 0.20 - 0.50 Spacer tool 51.4 +0.05...
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Beverly 125 Characteristics 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.
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Beverly 125 Characteristics 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.
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Beverly 125 Characteristics Oversizes OVERSIZES Name Description Dimensions Initials Quantity Compression ring 1st 57.2 x 1 0.15 ÷ 0.30 oversize Oil scraper ring 1st 57.2 x 1 0.10 ÷ 0.30 Oversize Oil scraper ring 1st 57.2 x 2.5 0.15 ÷ 0.35...
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Beverly 125 Characteristics Product Description Specifications AGIP CITY HI TEC 4T Engine oil SAE 5W-40, API SL, ACEA A3, JASO MA Synthetic oil AGIP BRAKE 4 Brake fluid FMVSS DOT 4 Synthetic fluid AGIP PERMANENT SPEZIAL coolant Monoethylene glycol-based antifreeze...
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Beverly 125 Tooling APPROPRIATE TOOLS Stores code Description 020151Y Air heater 020331Y Digital multimeter 020648Y Single battery charger 001467Y014 Pliers to extract ø 15-mm bearings 020412Y 15 mm guide TOOL - 23...
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Beverly 125 Tooling Stores code Description 020335Y Magnetic support for dial gauge 020565Y Flywheel lock calliper spanner 020439Y 17 mm guide 020359Y 42x47-mm adaptor 020363Y 20 mm guide TOOL - 24...
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Beverly 125 Tooling Stores code Description 020459Y 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...
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Beverly 125 Tooling Stores code Description 020424Y 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 TOOL - 26...
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Beverly 125 Tooling Stores code Description 020375Y 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...
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Beverly 125 Tooling Stores code Description 020319Y 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 TOOL - 28...
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Beverly 125 Tooling Stores code Description 020426Y 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 re- moval tool TOOL - 29...
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Beverly 125 Tooling Stores code Description 020455Y 10-mm guide 020442Y Pulley lock wrench 020440Y Water pump service tool 020329Y MityVac vacuum-operated pump 020357Y Adaptor 32 x 35 mm 020409Y Multimeter adaptor - Peak voltage detec- tion TOOL - 30...
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Beverly 125 Tooling Stores code Description 020456Y 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...
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Beverly 125 Tooling Stores code Description 020454Y 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 125 Maintenance Maintenance chart EVERY 2 YEARS Action Coolant - change Brake fluid - change Secondary air filter (external / internal) - Clean EVERY 3,000 KM Action Engine oil - level check/ top-up 1,000 FTER Action Engine oil - replacement...
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Beverly 125 Maintenance Action Transmission elements - lubrication Safety locks - check Suspensions - check Electrical system and battery - check Headlight - adjustment Tyre pressure and wear - check Vehicle and brake test - road test Driving belt - replacement (*) See instructions in the «Idle speed adjustment»...
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Beverly 125 Maintenance Action Tyre pressure and wear - check Vehicle and brake test - road test Engine oil - replacement Oil filter -Replacement 36,000 FTER Action Engine oil - replacement Hub oil level - check Spark plugs - replacement...
Beverly 125 Maintenance 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.
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Beverly 125 Maintenance - 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...
Beverly 125 Maintenance Spark plug - Rest the scooter on its centre stand - Open the cap on the right hand side of the vehicle and remove the corresponding screw by lifting the lower part in the specific groove; - Disconnect spark plug HV wire hood;...
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Beverly 125 Maintenance Hub oil Check -Stand the vehicle on its centre stand on flat ground; - Remove the oil dipstick «A», dry it with a clean cloth and put it back into its hole tighten- ing it completely; -Take out the dipstick checking that the oil level reaches the dipstick bottom notch (see figure);...
Beverly 125 Maintenance Air filter - Remove the left side panel. - Remove the air cleaner cover after unscrewing the 9 fixing screws. - Take out the filtering element. - Replace the air filter with a new one. N.B. EVERY 6,000 KM CHECK THE AIR FILTER AND IF RE- QUIRED, CLEAN IT WITH COMPRESSED AIR.
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Beverly 125 Maintenance Replacement Change oil as indicated in the scheduled mainte- nance table. The engine must be emptied by drain- ing the oil through the drainage plug «B» of the mesh pre-filter, flywheel side; furthermore, to fa- cilitate oil drainage, loosen the cap/dipstick «A».
Beverly 125 Maintenance This operation must be carried out with the engine cold and following the procedure below: 1) Rest the scooter on the central stand and on a flat ground. 2) Unscrew the cap/dipstick "A", dry it with a clean cloth and reinsert it, screwing it thoroughly.
Beverly 125 Maintenance 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.
Beverly 125 Maintenance Discharge: 0.15 mm (when cold) Cooling system Level check - To check the level, it is necessary to look inside the expansion tank: a mark on the side of the filler indicates MIN and MAX levels. Top-up...
Beverly 125 Maintenance Braking system Level check The brake fluid tanks for the front and rear brakes are located on the pumps under the handlebar cover. Proceed as follows: - Bring the scooter onto the centre stand and with the handlebar centred; - check the fluid level at the sight glass as shown in the figure.
Beverly 125 Maintenance EXCEEDS A CERTAIN VALUE, BRAKING WILL BE INEF- FICIENT. NEVER USE BRAKE LIQUID IN OPEN OR PARTIALLY USED CONTAINERS. UNDER NORMAL CLIMATIC CONDITIONS, THE FLUID MUST BE CHANGED EVERY 20,000 KM OR ANYWAY EV- ERY TWO YEARS.
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Beverly 125 Maintenance - Remove the plastic support and the gasket as shown in the photograph - 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. Re- place them if damaged or abnormally distorted.
Beverly 125 Troubleshooting Engine Poor performance POOR PERFORMANCE Possible Cause Operation The carburettor is dirty; fuel pump or vacuum valve damaged Remove, wash with solvent and dry with compressed air or re- place Excess of encrustations in the combustion chamber...
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Beverly 125 Troubleshooting Possible Cause Operation The carburettor is dirty; fuel pump or vacuum valve damaged Remove, wash with solvent and dry with compressed air or re- place Battery flat Check the charge of the battery, if there are any sulphur marks,...
Beverly 125 Troubleshooting Possible Cause Operation The starter remains on Check: electric wiring, circuit not interrupted, mechanical movement and power supply; replace if necessary Minimum nozzle dirty Wash the nozzle with solvent and dry with compressed air Excessive exhaust noise...
Beverly 125 Troubleshooting Insufficient braking NSUFFICIENT BRAKING Possible Cause Operation Inefficient braking system Check the pad wear (1.5 min). Check that the brake discs are not worn, scored or warped. Check the correct level of fluid in the pumps and change brake fluid if necessary. Check there is no air in the circuits;...
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Beverly 125 Troubleshooting Possible Cause Operation If by operating the turn indicator control the lights are not stead- ily on, replace the control unit; otherwise, check the cable harness and the switch. Steering and suspensions Heavy steering STEERING HARDENING Possible Cause...
Beverly 125 Electrical system 39. Fuel level transmitter 40. Instrument panel F. Fuel gauge G. Low fuel warning light I. Oil warning light J. Water temperature gauge 46. Key switch Devices and accessories 1. Electronic ignition device 4. Side stand switch 5.
Beverly 125 Electrical system 21. Helmet compartment light switch 23. Helmet compartment internal light 25. Rear left turn indicator 27. Rear right turn indicator 28. Front left turn indicator 30. Front right turn indicator 31. Horn 32. Horn button 33. Electric fan 34.
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Beverly 125 Electrical system switch is set to «OFF». It remains activated for 48 hours in order not to affect the battery charge. When the ignition switch is turned to «ON», the deterring blinker function is deactivated. Subse- quently, a flash confirms the switching to « ON».
Beverly 125 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 evi- dent loss of power may be felt.
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Beverly 125 Electrical system After the failure code indication, a steadily on LED signals that ignition is disabled; see the table: Diagnostic code - 2 flashes When the 2-flash code is detected, carry out the following checks: - Check if the failure continues after changing key (MASTER key included). If the failure persists with any key, disconnect the aerial connector from the control unit and check the aerial for continuity with the recommended tool.
Beverly 125 Electrical system Example with programmed control unit, trans- ponder, programmed key and working aerial. The ignition is enabled (regular use conditions) 3-FLASH CODE - Example with programmed control unit, aerial working properly and unknown trans- ponder code. Ignition disabled-Vehicle immobilised...
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Beverly 125 Electrical system 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 har- ness.
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Beverly 125 Electrical system Pick-Up. - Disconnect the control unit connector and con- nect 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.
Beverly 125 Electrical system Stator check Disconnect the connector from the voltage regu- lator and check there is continuity between any yellow cable and the other two cables. Electric characteristic Ohm value: 0.7 ÷ 0.9 Ohm Also check that all yellow cables are insulated from the ground connection.
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Beverly 125 Electrical system Recharge system voltage check 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 the ground lead and to the battery positive terminal passing through the 15A protection fuse (No.
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Beverly 125 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 volt- age, check the connection cable harness to the key switch and that the 15A fuse (No.
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Beverly 125 Electrical system If no voltage is detected, check the cable harness, the connections and make sure the 15A main fuse (No. 7) is in good conditions; otherwise, proceed as follows: - Jump terminals No. 1 (Blue-Black) and No. 4 (Red-Black) (see figure) and turn the turn indicator switch alternately to the right and left.
Beverly 125 Electrical system FUSE TABLE Specification Desc./Quantity Fuse No. 1 Position on fuse holder:1 Capacity: 7.5 A Protected circuits: Front tail light - Rear tail light - In- strument panel lighting - License plate light Location: Front case Fuse No. 2 Position on fuse holder:2 Capacity: 7.5 A...
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Beverly 125 Electrical system 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.
Beverly 125 Electrical system 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 - ). Pump electrics check Connect the tester positive probe to pin 4 of the...
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Beverly 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.
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Beverly 125 Engine from vehicle - Remove the rear brake calliper and release the hoses from the scooter. - Remove the left shock absorber lower retainer. - Remove the throttle grip transmission. - Detach the air filter sleeve and the manifold shown in the figure.
Beverly 125 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.
Beverly 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...
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Beverly 125 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.
Beverly 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.
Beverly 125 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...
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Beverly 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 CEN- TRAL CONTACT SURFACE AND MUST NOT BE DIFFER- ENT FROM ONE ANOTHER.
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Beverly 125 Engine Removing the driven half-pulley bearing - Check there are no signs of wear and/or noisi- ness; - Replace with a new one if there are. - Remove the retaining ring using two flat blade screwdrivers. - Support the pulley bushing adequately from the threaded side using a wooden surface.
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Beverly 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...
Beverly 125 Engine Refitting the driven pulley - Insert the new oil guards and O-rings on the mov- able half-pulley. - Lightly grease the O-rings (A) shown in the figure. - Fit the half-pulley over the bushing using the ap-...
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Beverly 125 Engine Inspecting the clutch spring - Measure the length of the spring, while it is re- laxed. Characteristic Standard length 106 mm acceptable limit after use: 101 mm Refitting the clutch - Support the driven pulley spring compressor ap- propriate tool with the control screw in vertical axis.
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Beverly 125 Engine - Loosen the tool clamp and insert the belt accord- ing to its direction of rotation. - Lock the driven pulley again using the specific tool. - Preload the clutch return spring with a traction/ rotation combined action until it reaches the pul- leys maximum opening and place the belt on the minimum rolling diameter.
Beverly 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;...
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Beverly 125 Engine Inspecting the rollers case - Check that the internal bushing shown in the fig- ure is not abnormally worn and measure inner diameter A. - Measure outer diameter B of the pulley sliding bushing shown in the figure.
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Beverly 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.
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Beverly 125 Engine - Rotate the engine manually until the belt is slight- ly taut. CAUTION IT IS EXTREMELY IMPORTANT THAT THE BELT IS PER- FECTLY FREE WHEN THE FIXED DRIVING HALF-PULLEY IS ASSEMBLED. THIS IS TO AVOID CARRYING OUT A WRONG TIGHTENING OF THE DRIVING HALF-PULLEY.
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Beverly 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.
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Beverly 125 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.
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Beverly 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.
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Beverly 125 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.
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Beverly 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.
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Beverly 125 Engine Refitting the ub cover - Fit a new gasket together with the centring dow- els. - 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.
Beverly 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.
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Beverly 125 Engine Refitting the stator - Refit the stator and flywheel carrying out the re- moval procedure in reverse, tightening the retain- ers to the specified torque. - Place the cable harness as shown in the figure. - Stator screws and Pick-Up N.B.
Beverly 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...
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Beverly 125 Engine - Insert the special flywheel stop tool on the fly- wheel 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...
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Beverly 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.
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Beverly 125 Engine - Insert the free wheel on the flywheel as shown in the photo - Then refit the flywheel with free wheel and trans- mission gear - Using the special flywheel stop tool, tighten up the flywheel fixing nut to the prescribed torque...
Beverly 125 Engine Refitting the starter motor - Fit a new O-ring on the starter motor and lubricate - 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.
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Beverly 125 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 separa- tion washer.
Beverly 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.
Beverly 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.
Beverly 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 RECOG- NISE THEIR ORIGINAL POSITION ON THE HEAD.
Beverly 125 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.
Beverly 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...
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Beverly 125 Engine Top piston ring - standard coupling clearance Top piston ring - maximum clear- 0.025 ÷ 0.07 mm ance allowed after use Middle piston 0.08 mm ring - standard coupling clearance 0.015 - 0.06 mm Middle piston ring - maximum clearance al-...
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Beverly 125 Engine zes. They are also classified into 4 categories A- A, 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 di- ameter.
Beverly 125 Engine Removing the piston - Install piston and wrist pin onto the connecting rod, aligning the piston arrow the arrow facing to- wards the exhaust. - Fit the wrist pin stop ring onto the appropriate tool - With opening in the position indicated on the tool...
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Beverly 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.
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Beverly 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.
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Beverly 125 Engine 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.
Beverly 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 ca- pacities exhibit no wear.
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Beverly 125 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 as- sembly 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.
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Beverly 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.
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Beverly 125 Engine - 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.
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Beverly 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 - 128...
Beverly 125 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.
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Beverly 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 diame- Diameter 12.000 - 12.011 mm...
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Beverly 125 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.
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Beverly 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.
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Beverly 125 Engine Assemble the limiting bell using the counterweight fixing screw as a reference. - Tighten the clamping screw to the prescribed tor- que. Locking torques (N*m) Limiting bell screw 11 ÷ 15 Nm Set the tensioner cursor to the rest position.
Beverly 125 Engine Name Torque in Nm Slider screw 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.
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Beverly 125 Engine Before opening the engine crankcase, it is advis- able 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 sup- porting surfaces of the crankshaft casing.
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Beverly 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 crank- shaft between these surfaces, as shown in the diagram.
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Beverly 125 Engine 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.
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Beverly 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 com- partment and the oil ducts, the by-pass duct, the main bushings and the cooling jet on the trans- mission side (see diagram).
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Beverly 125 Engine THE HEAD LUBRICATION CHANNEL IS PROVIDED WITH A SHUTTER JET; THIS GIVES A "LOW PRESSURE" HEAD LUBRICATION; THIS CHOICE WAS MADE TO REDUCE THE OIL TEMPERATURE IN THE SUMP. THE JET CLOG- GING IMPAIRS THE HEAD LUBRICATION AND THE TIM- ING MECHANISMS.
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Beverly 125 Engine - The bushing housings in the crankcase are avail- able in two categories, Cat. 1 and Cat. 2, as are the crankshafts. - The main bushings are available in three thick- ness categories, identified by colour markings, as shown in the table below.
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Beverly 125 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 ÷...
Beverly 125 Engine Oil pressure check - After removing the flywheel cover as described in the "Flywheel" chapter, remove the electric con- nexion 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...
Beverly 125 Engine Crankshaft oil seals Removal - First remove the transmission cover and the com- plete 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.
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Beverly 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.
Beverly 125 Engine For 125 models, fit a new oil seal on the flywheel side using the specific tool as shown in the photo- graph N.B. FAILURE TO USE THE SPECIFIC TOOL CAN RESULT IN AN INCORRECT DEPTH POSITION AND AS A CONSE- QUENCE IN INADEQUATE OIL SEALING.
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Beverly 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 EN- SURE THAT THE INITIAL DIRECTION OF ROTATION IS MAINTAINED.
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Beverly 125 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.
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Beverly 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 "Trans- mission" chapter. - Drain the oil as described previously.
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Beverly 125 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.
Page 152
Beverly 125 Engine - Switch the pump to pressure mode (PRES- SURE). - Operate the pump slowly and check if there is an increase of pressure. A small leakage is consid- ered to be normal. If anomalies are detected, replace the pump.
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Beverly 125 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).
Page 154
Beverly 125 Engine - Remove the protection, the bracket and the start- er 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.
Page 155
Beverly 125 Engine - Remove the vacuum valve together with the di- aphragm. - Unscrew the bayonet joint 1/8 of a turn and re- move, take out the spring and vacuum valve nee- - Remove the 4 screws indicated in the figure.
Page 156
Beverly 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.
Page 157
Beverly 125 Engine -Remove the maximum nozzle. -Remove diffuser. ENG - 157...
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Beverly 125 Engine - Remove the sprayer. N.B. WHEN CLEANING THE CARBURETTOR BODY REMOVE THE SPRAYER TO AVOID LOSING PARTS. IF THE SPRAY- ER IS FORCED IN ITS HOUSING DO NOT ATTEMPT TO REMOVE IT AS THIS WILL ONLY DAMAGE IT.
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Beverly 125 Engine Kehin - Before refitting, wash the carburettor body accu- rately 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.
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Beverly 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.
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Beverly 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 accelera- tion pump pipes are clean.
Page 162
Beverly 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.
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Beverly 125 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 am- bient pressure intake.
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Beverly 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 de- formed or rusty.
Page 165
Beverly 125 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 possi- ble. - The correct warm up time depends on the ambi- ent temperature.
Beverly 125 Suspensions 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.
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Beverly 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,...
Page 169
Beverly 125 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...
Beverly 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 proper- - Tighten the wheel axle nut to the prescribed tor- que.
Beverly 125 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...
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Beverly 125 Suspensions Removal - Remove the front wheel. - Remove the handlebar. - Using the appropriate tool, loosen and remove the upper ring nut, the distancing washer, the counter ring nut and the spacer ring. - Extract the fork.
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Beverly 125 Suspensions - Insert the retaining band of the two half-rings. - Using a 19 mm hexagonal spanner, extract the roller bearing. Specific tooling 020458Y Puller for lower bearing on steering tube - Insert the a new plate and a new dust guard in the steering tube - Insert a new roller bearing in the roller tube.
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Beverly 125 Suspensions - Loosen the stem support clamp and remove fork leg and stem. - Remove the first spring featuring 15 turns. - Remove the spring support plate. - Remove the second spring featuring 21 turns. - Drain the oil.
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Beverly 125 Suspensions - Keeping the tie rod in vertical position, insert the bell for the Ø 35 mm stems. - Insert the nut in the thread and take out the oil guard Specific tooling 020487Y Fork oil seal extractor - Check the length of the springs.
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Beverly 125 Suspensions - Insert a new oil guard with the special adaptor handle and take it to the stop. - Insert the safety clip. - Insert a new dust guard. - Insert the contrast spring into the pumping mem- ber.
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Beverly 125 Suspensions - Insert the stem into the fork clamp. - Do up the clamp once to allow the stem closure upper cap to be tightened. - Check that the sealing ring on the cap is in good working order, then tighten the cap on the stem to the prescribed torque.
Beverly 125 Suspensions Specific tooling 020055Y Wrench for steering tube ring nut Locking torques (N*m) Steering lower ring nut 10 ÷ 13 then loosen by 90° Upper steering ring nut 30 ÷ 36 Steering bearing Removal - Remove the fork...
Beverly 125 Suspensions - Using two 24 mm wrenches, tighten the screw until the seat and the bearing are fully set in place. N.B. ALWAYS USE A NEW BEARING AND A NEW SEAT. Specific tooling 001330Y Tool for fitting steering seats...
Page 180
Beverly 125 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.
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Beverly 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...
Page 182
Beverly 125 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.
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Beverly 125 Suspensions - Using an appropriate tool plant new roller cas- ings, being careful to position the bearings with the O-rings facing outwards Specific tooling 020115Y Ø 18 punch 020244Y 15-mm diameter punch SWINGING ARM SERVICE Specification Desc./Quantity Length of the internal swinging arm spacer on the frame side 228 -0.2/-0.4 mm...
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Beverly 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 Torque in Nm Part 1 64 ÷...
Beverly 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 clamp-...
Page 186
Beverly 125 Suspensions Removal - Loosen and remove the lower retaining bolt of the right-hand shock absorber at the support arm. - Loosen the 2 retaining screws between arm and engine. - Remove the split pin and safety cover; unscrew the wheel axle nut;...
Beverly 125 Suspensions - 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 Refitting To refit, carry out the removal operations in reverse order, observing the prescribed tightening torques.
Beverly 125 Suspensions 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 Locking torques (N*m) stand retaining bolt 20 ÷...
Beverly 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. COL- LECTION AND DISPOSAL MUST BE CARRIED OUT IN COMPLIANCE WITH THE REGULATIONS IN FORCE.
Beverly 125 Braking system Refitting - Fix the brake calliper support plate to the crank- case and the brake calliper to the bracket, tight- ening the screws to the prescribed torque. - Apply the recommended product to the fixing screws of the brake calliper to the bracket.
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Beverly 125 Braking system Overhaul Proceed as follows: 1) remove the two male hexagonal screws (1) and take out the two pads (10); 2) remove the two male hexagonal screws (2) and remove the reaction plate (3); 3) take out the fixed plate (4) from the guide;...
Beverly 125 Braking system The body and the reaction plate body work inte- grally and can move axially with respect of the fixed plate that is integral to the strut. The pistons, forced by pressure to push the pad to the disk, cause the reaction plate to push in turn the other pad towards the disc.
Beverly 125 Braking system Removal - Remove the rear wheel. - Remove the hub and the brake disc. - Carry out the same procedure with the front brake disc. See also Removing the rear wheel Refitting - For the installation, position the disc correctly using the arrow stamped on it as reference.
Beverly 125 Braking system - Remove the wheel and check using the appro- priate tools that the axial run-out of the brake surface is within the prescribed limits. - If this is not the case, replace the disc and repeat the test.
Beverly 125 Braking system Disc Inspection Checking the disc is important; it must be perfectly clean, with no sign of rust, oil or grease or any oth- er dirt, and must show no signs of deep scoring. Characteristic Thickness of a new front disc 4.0 mm...
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Beverly 125 Braking system Refitting To fit, proceed as follows: - Insert the two pads in the callipers. - Screw the two pad lock pins to the correct torque, and apply the recommended product. - Fit the calliper on its support, tightening the two screws to the prescribed torque.
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Beverly 125 Braking system Pad fastening pin 19.6 ÷ 24.5 Screw tightening calliper to the support 20 ÷ 25 Fixing screws for the calliper support on the engine 20 ÷ 25 Fill Rear - combined Proceed as follows: - Position the vehicle on a flat surface and on the...
Page 199
Beverly 125 Braking system 020329Y MityVac vacuum-operated pump Locking torques (N*m) Oil bleed screw 12 - 16 Front Proceed as follows: - Position the vehicle on a flat surface and on the stand - Loosen the two screws shown in the figure and open the front brake fluid reservoir.
Page 200
Beverly 125 Braking system Locking torques (N*m) Oil bleed screw 12 - 16 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.
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Beverly 125 Braking system 7. Gasket 8. Spring 9. Tank CAUTION ALL THE SEALS AND GASKETS MUST BE REPLACED EVERY TIME THE PUMP IS SERVICED. Refitting - Upon refitting, perform the operation but in reverse order. - Tighten the hydraulic line to the prescribed torque and purge the system.
Page 202
Beverly 125 Braking system Rear handlebar cover Rear - combined 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.
Beverly 125 Cooling system COOLING CIRCUIT Specification Desc./Quantity Carburettor heating circuit Thermostat with by-pass Expansion tank Radiator Water pump - overhaul - Check the water pump if noise in the bearings or liquid leaking from the drainage hole inside the cover is detected.
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Beverly 125 Cooling system COOL SYS - 206...
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Beverly 125 Cooling system Check components - Check that the rotor does not show abnormal wear or dents; - Check that the rotor shaft is not rusty; - Check that there is no rust on the bearing seats or the ceramic seal;...
Page 208
Beverly 125 Cooling system - Insert the flywheel cover with bearings on the ap- propriate tool. - Insert the shaft together with the mechanical gas- kets on the bearings. - With the appropriate punch and socket, insert the shaft in the bearings and the drive until the end of stroke of the appropriate tool cannot be seen.
Page 209
Beverly 125 Cooling system Removal - Loosen the two screws indicated in the figure and remove the thermostat cover. - Remove the thermostat with its gasket. Check - Visually check that the thermostat is not dam- aged. - Prepare a metal container with approx. 1 litre of water.
Page 210
Beverly 125 Cooling system 1) Look to see that the thermostat is not damaged. 2) Fill a metal container with approx. 1 litre of wa- ter. Immerse the thermostat, and keep it in the centre of the container. Immerse the multimeter temperature probe draw- ing No°...
Page 212
Beverly 125 Chassis Seat - Remove the saddle by loosening the three re- taining 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.
Page 213
Beverly 125 Chassis Rear handlebar cover - Remove the front handlebar cover. - Remove the 3 screws shown in the photograph. - Remove the 2 screws on the rear part of the han- dlebar cover shown in the photograph. See also...
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Beverly 125 Chassis Headlight assy. - Remove the headlight assembly by loosening the 4 fixing screws, two of which are shown in the fig- ure and two located further down. - Separate the electrical connectors; - Pull out the headlight as- sembly.
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Beverly 125 Chassis - Loosen the 2 screws shown in the figure. - Remove the legshield. See also Frame central cover Headlight assy. Knee-guard - Remove the legshield; - Remove the 2 fixing screws of the fuse box in the front glove box; - Separate the electrical connections;...
Page 216
Beverly 125 Chassis 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.
Page 217
Beverly 125 Chassis Removing the ignition key-switch when on *lock* In position "Lock", it is not possible to access the cylinder retaining spring. The spring must then be removed as shown in the figure, allowing the lock spring to be pressed out.
Page 218
Beverly 125 Chassis 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...
Beverly 125 Chassis See also Seat Rear rack Frame central cover Taillight assy. Taillight assy. Frame central cover Seat Rear rack Rear mudguard - Loosen the 4 fixing screws, 2 of which are indi- cated in the figure and the other 2 located on the opposite side under the air filter;...
Page 220
Beverly 125 Chassis Helmet bay - Remove the side fairings; - Disconnect the elec- trical 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;...
Beverly 125 Chassis - Remove the shield back plate. - Remove the front wheel housing. - Remove the footrest. N.B. THIS OPERATION SHOULD PREFERABLY BE PER- FORMED WITH THE TANK EMPTY. - Separate the electrical connections of the fuel gauge and disconnect the fuel supply line and tank breather;...
Beverly 125 Chassis 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.
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Beverly 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 Lock check - Safety locks...
Page 225
Beverly 125 Pre-delivery - 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.
Beverly 125 Pre-delivery - 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.
Beverly 125 Time Cylinder assy. CYLINDER- PISTON Code Action Duration 001002 Cylinder-Piston - Replacement 001154 Pin ring piston unit - Service TIME - 231...
Beverly 125 Time Air cleaner AIR CLEANER Code Action Duration 001014 Air filter - Replacement/Cleaning 001015 Air filter box - Replacement 004122 Carburettor air cleaner attachment - Replacement TIME - 245...
Page 246
Beverly 125 Time Frame CHASSIS Code Action Duration 004001 Chassis - Replacement TIME - 246...
Page 247
Beverly 125 Time Centre-stand CENTRE AND SIDE STANDS Code Action Duration 004004 Stand - Replacement 004102 Side stand - Replacement 005079 Stand switch - Replacement TIME - 247...
Beverly 125 Time Side fairings SIDE COVERS Code Action Duration 004085 Fairing (1) - Replacement 004012 Rear side panels - Replacement 004052 Bumper - Replacement TIME - 249...
Page 250
Beverly 125 Time Footrests MATS AND COVERS Code Action Duration 004075 Front mat - Replacement 004079 Passenger footrest (1) - Replace- ment 004015 Footrests - Remov. and Refit. TIME - 250...
Beverly 125 Time Rear cover REAR SHIELD Code Action Duration 004065 Legshield rear section - Remov. and Refit. 004081 Glove box door - Replacement TIME - 251...
Page 252
Beverly 125 Time Central cover CENTRAL COVER Code Action Duration 004011 Frame central cover - Replacement 002082 Fuel tank cap opening drive - Re- placement TIME - 252...
Beverly 125 Time Expansion tank EXPANSION TANK Code Action Duration 007001 Expansion tank - Replacement 007013 Expansion tank - radiator connection pipe - Replacement 001052 Coolant and air bleeding - Replace- ment TIME - 256...
Page 257
Beverly 125 Time Radiator RADIATOR Code Action Duration 007014 Radiator thermal switch - Replace- ment 007002 Radiator water - Replacement 007016 Complete fan with support - Replace- ment 007003 Coolant delivery and return pipe - Re- placement TIME - 257...
Beverly 125 Time Handlebar covers HANDLEBAR COVER Code Action Duration 004018 Handlebar front section - Replace- ment 004019 Handlebar rear section - Replace- ment 006013 Handlebar front part - Painting 006014 Handlebar rear part - Painting TIME - 260...
Beverly 125 Time Brake hoses BRAKE PIPING Code Action Duration 002039 Front brake calliper - Replacement 002040 Front brake calliper - Service 002021 Front brake piping - Replacement 002047 Front brake fluid and system bleed- ing plug - Repl. 003070...
Page 264
Beverly 125 Time Seat SADDLE Code Action Duration 004003 Saddle - Replacement TIME - 264...
Beverly 125 Time Front wheel FRONT WHEEL Code Action Duration 002041 Brake disc - Replacement 003037 Front wheel rim - Remov. and Refit. 003038 Front wheel axle - Remov. and Refit. 003040 Front wheel bearings - Replacement 003047 Front tyre - Replacement...
Beverly 125 Time ELECTRICAL START UP Code Action Duration 001141 Belt anti-vibration roller - Replace- ment 001020 Starter motor - Replacement 001017 Start-up pinion - Replacement Version 125 TIME - 272...
Page 273
Beverly 125 Time ELECTRICAL START-UP Code Action Duration 001020 Starter motor - Replacement 001017 Start-up pinion - Replacement Fuel pump TIME - 273...
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