Name: PIAGGIO BV 500 USA
Brand: PIAGGIO
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WORKSHOP MANUAL

633387

Beverly 500 i.e.

Index of Topics4
Characteristics5
Safety Rules6
Maintenance Rules6
Vehicle Identification7
Dimensions and Mass7
Engine7
Transmission8
Capacities8
Electrical System8
Frame and Suspensions9
Brakes9
Wheels and Tyres9
Tightening Torques9
Brake System10
Front Suspension10
Rear Suspension10
Crankcase and Crankshaft11
Final Reduction11
Transmission Cover11
Overhaul Data12
Cylinder - Piston Assy12
Assembly Clearances12
Piston Rings13
Crankcase - Crankshaft - Connecting Rod13
Slot Packing System15
Products16
Maintenance17
Maintenance Chart18
Spark Plug22
Check23
Replacement23
Air Filter24
Engine Oil24
Engine Oil Filter25
Oil Pressure Warning Light27
Checking the Valve Clearance27
Cooling System27
Level Check28
Braking System28
Top-Up29
Headlight Adjustment30
Checking the End Compression Pressure31
Electrical System32
Components Arrangement35
Ignition38
Headlights and Automatic Starter Section39
Battery Recharge and Starting40
Level Indicators and Enable Signals Section41
Turn Signal Lights42
Checks and Inspections43
Battery Recharge Circuit43
Stator Check43
Recharge System Voltage Check44
Fuses45
Sealed Battery46
Dry-Charge Battery47
Connectors49
Dashboard49
Engine from Vehicle51
Exhaust Assy. Removal52
Removal of the Engine from the Vehicle52
Engine54
Automatic Transmission55
Transmission Cover55
Air Duct56
Air Duct Filter57
Removing the Driven Pulley Shaft Bearing57
Refitting the Driven Pulley Shaft Bearing58
Baffle Roller58
Plastic Roller58
Removing the Driven Pulley59
Inspecting the Clutch Drum59
Removing the Clutch60
Pin Retaining Collar60
Removing the Driven Half-Pulley Bearing61
Inspecting the Driven Fixed Half-Pulley62
Inspecting the Driven Sliding Half-Pulley62
Refitting the Driven Half-Pulley Bearing62
Refitting the Driven Pulley63
Inspecting the Clutch Spring64
Refitting the Clutch65
Drive-Belt66
Removing the Driving Pulley66
Inspecting the Rollers Case67
Refitting the Driving Pulley69
Refitting the Transmission Cover71
End Gear73
Removing the Hub Cover73
Removing the Wheel Axle73
Removing the Hub Bearings73
Removing the Wheel Axle Bearings74
Inspecting the Hub Shaft75
Inspecting the Hub Cover76
Refitting the Hub Cover Bearings78
Refitting the Hub Bearings79
Refitting the Ub Cover79
Flywheel Cover80
Removing the Flywheel Cover Components81
Removing the Stator82
Inspecting the Cover Components85
Refitting the Stator87
Refitting the Flywheel Cover Components88
Refitting the Flywheel Cover90
Flywheel and Starting92
Removing the Starter Motor95
Removing the Flywheel Magneto95
Inspecting the Flywheel Components98
Starter Gear Rim99
Intermediate Gear99
Refitting the Free Wheel100
Refitting the Intermediate Gear101
Refitting the Flywheel Magneto102
Refitting the Starter Motor104
Cylinder Assy. and Timing System104
Removing the Intake Manifold105
Removing the Rocker-Arms Cover105
Removing the Timing System Drive105
Removing the Cam Shaft108
Removing the Cylinder Head108
Removing the Valves110
Removing the Cylinder - Piston Assy111
Inspecting the Small End112
Inspecting the Wrist Pin112
Inspecting the Piston113
Inspecting the Piston Rings114
Removing the Piston114
Choosing the Gasket115
Refitting the Piston Rings117
Refitting the Cylinder117
Inspecting the Cylinder Head117
Inspecting the Timing System Components118
Inspecting the Valve Sealings119
Inspecting the Valve Housings119
Inspecting the Valves120
Inspecting the Valve Stem Guide Clearance121
Inspecting the Springs and Half-Cones122
Refitting the Valves123
Inspecting the Cam Shaft123
Refitting the Head and Timing System Components125
Refitting the Timing Chain132
Inspecting the Radial Air Gap133
Refitting the Rocker-Arms Cover135
Refitting the Intake Manifold136
Crankcase - Crankshaft136
Splitting the Crankcase Halves138
Removing the Crankshaft138
Removing the Countershaft139
Replacing the Countershaft Bearings140
Inspecting the Crankshaft Components142
Inspecting the Crankshaft Alignment143
Inspecting the Crankcase Halves145
Inspecting the Crankshaft Plain Bearings146
Coupling Chart147
Countershaft147
Refitting the Crankshaft147
Refitting the Crankcase Halves149
Lubrication151
Oil Pump152
Oil Filter152
Conceptual Diagrams153
General Characteristics153
Diagnosis Guide154
Oil Pressure Check156
Oil Pump157
Injection163
Precautions173
Terminals Setup173
EMS Circuit Diagram176
Troubleshooting Procedure177
Engine Does Not Start177
Starting Difficulties177
Engine Stops at Idle178
Engine Does Not Rev down178
Exhaust Backfires in Deceleration179
Engine Revs Irregularly179
Poor Performance at Full Throttle180
Engine Knocking180
Decoder Master-Box Circuit180
Constant Supply Circuit Check181
Key-Switch Power Supply Circuit Check182
Diagnostic Circuit185
Injection Warning Light Circuit187
Self-Diagnosis System188
Fuel Supply System190
Circuit Diagram191
Removing the Injector191
Refitting the Injector192
Refitting the Butterfly Valve194
Pump Supply Circuit194
Circuit Check195
Circuit Leak Test198
Pressure Regulator Check199
Fuel Pump and Filter Check200
Resistor Check203
Pump Consumption Check204
Fuel Filter Check204
Pump Bracket Overhaul205
Pump Bracket Installation209
Inspecting the Injector Circuit209
Inspecting the Injector Hydraulics213
Troubleshooting214
Immobiliser Circuit215
System Components215
Virgin Circuit216
Setting the Circuit218
LED Signals218
Deterring Blink219
Checking Master-Box Data219
Resetting the Circuit219
Diagnostic Codes220
Tachometer224
Circuit Diagram229
Inspecting the Spark Plug Shielded Cap234
Spark Advance235
Coolant Temperature Sensor236
Intake Air Temperature Sensor241
Pressure Sensor247
Throttle Valve Opening Sensor247
Zeroing the Throttle252
Step Motor254
Suspensions260
Removing the Front Wheel261
Front Wheel Hub Overhaul261
Refitting the Front Wheel263
Front Fork264
Overhaul264
Steering Bearing270
Removing the Rear Wheel272
Refitting the Rear Wheel273
Swing-Arm273
Shock Absorbers282
Centre-Stand283
Side Stand283
Braking System284
Rear Brake Calliper285
Front Brake Calliper288
Rear Brake Disc290
Disc Inspection291
Front Brake Disc292
Front Brake Pads293
Rear Brake Pads295
Rear - Combined296
Brake Fluid Level Check298
Front Brake Pump299
Cooling System301
Circuit Diagram302
Electric Fan Check303
System Sealing Check305
Coolant Replacement305
Water Pump - Overhaul306
Thermostat307
Excessive System Pressure309
Cooling Fluid Consumption309
Oil in the Fluid309
Chassis310
Seat311
Side Fairings311
Rear Rack311
Rear Handlebar Cover312
Instrument Panel313
Front Handlebar Cover313
Headlight Assy.313
Frame Central Cover314
Legshield314
Knee-Guard315
Removing the Ignition Key-Switch When on *Off*317
Removing the Ignition Key-Switch When on *Lock*318
Taillight Assy.318
Footrest319
License Plate Holder321
Air Filter322
Rear Mudguard322
Helmet Bay323
Spoiler323
Fuel Tank324
Rear Central Cover326
Front Mudguard327
Radiator Fan328
Pre-Delivery329
Aesthetic Inspection330
Tightening Torques Inspection330
Electrical System330
Levels Check331
Road Test331
Static Test331
Functional Inspection332
Time333
Engine334
Crankcase335
Crankshaft336
Cylinder Assy.337
Cylinder Head Assy.338
Rocker Arms Support Assy.339
Cylinder Head Cover340
Flywheel Cover341
Driven Pulley342
Final Gear Assy.343
Driving Pulley344
Transmission Cover345
Starter Motor346
Flywheel Magneto347
Butterfly Valve348
Exhaust Pipe349
Air Cleaner350
Frame351
Legshield Spoiler352
Footrests354
Rear Cover355
Central Cover356
Underseat Compartment357
Mudguard358
Expansion Tank360
Radiator361
Rear Shock-Absorber362
Steering Column Bearings363
Handlebar Covers364
Handlebar Components365
Swing-Arm366
Brake Hoses367
Seat Lock369
Instrument Panel370
Rear Rack371
Locks372
Turn Signal Lights373
Front Wheel374
Rear Wheel375
Fuel Pump376
Electric Devices377
Brake Callipers380

Brand	PIAGGIO
Model	BV 500 USA
Category	Scooter
Language	English

PIAGGIO BV 500 USA User Manual

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PIAGGIO BV 500 USA Specifications

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