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PIAGGIO
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BV 500 USA
PIAGGIO BV 500 USA User Manual
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IMMOBILIZER DECODER
Specification
Desc./Quantity
1
-
2
Immobilizer LED control
(negative)
3
Base power supply
(positive)
4
Negative
5
-
6
Electronic control unit EMS
(serial)
7
-
8
Continuous power supply (positive)
Immobilizer aerial
Beverly 500 i.e.
Injection
INJEC - 175
174
176
Table of Contents
Index of Topics
4
Characteristics
5
Safety Rules
6
Maintenance Rules
6
Vehicle Identification
7
Dimensions and Mass
7
Engine
7
Transmission
8
Capacities
8
Electrical System
8
Frame and Suspensions
9
Brakes
9
Wheels and Tyres
9
Tightening Torques
9
Brake System
10
Front Suspension
10
Rear Suspension
10
Crankcase and Crankshaft
11
Final Reduction
11
Transmission Cover
11
Overhaul Data
12
Cylinder - Piston Assy
12
Assembly Clearances
12
Piston Rings
13
Crankcase - Crankshaft - Connecting Rod
13
Slot Packing System
15
Products
16
Maintenance
17
Maintenance Chart
18
Spark Plug
22
Check
23
Replacement
23
Air Filter
24
Engine Oil
24
Engine Oil Filter
25
Oil Pressure Warning Light
27
Checking the Valve Clearance
27
Cooling System
27
Level Check
28
Braking System
28
Top-Up
29
Headlight Adjustment
30
Checking the End Compression Pressure
31
Electrical System
32
Components Arrangement
35
Ignition
38
Headlights and Automatic Starter Section
39
Battery Recharge and Starting
40
Level Indicators and Enable Signals Section
41
Turn Signal Lights
42
Checks and Inspections
43
Battery Recharge Circuit
43
Stator Check
43
Recharge System Voltage Check
44
Fuses
45
Sealed Battery
46
Dry-Charge Battery
47
Connectors
49
Dashboard
49
Engine from Vehicle
51
Exhaust Assy. Removal
52
Removal of the Engine from the Vehicle
52
Engine
54
Automatic Transmission
55
Transmission Cover
55
Air Duct
56
Air Duct Filter
57
Removing the Driven Pulley Shaft Bearing
57
Refitting the Driven Pulley Shaft Bearing
58
Baffle Roller
58
Plastic Roller
58
Removing the Driven Pulley
59
Inspecting the Clutch Drum
59
Removing the Clutch
60
Pin Retaining Collar
60
Removing the Driven Half-Pulley Bearing
61
Inspecting the Driven Fixed Half-Pulley
62
Inspecting the Driven Sliding Half-Pulley
62
Refitting the Driven Half-Pulley Bearing
62
Refitting the Driven Pulley
63
Inspecting the Clutch Spring
64
Refitting the Clutch
65
Drive-Belt
66
Removing the Driving Pulley
66
Inspecting the Rollers Case
67
Refitting the Driving Pulley
69
Refitting the Transmission Cover
71
End Gear
73
Removing the Hub Cover
73
Removing the Wheel Axle
73
Removing the Hub Bearings
73
Removing the Wheel Axle Bearings
74
Inspecting the Hub Shaft
75
Inspecting the Hub Cover
76
Refitting the Hub Cover Bearings
78
Refitting the Hub Bearings
79
Refitting the Ub Cover
79
Flywheel Cover
80
Removing the Flywheel Cover Components
81
Removing the Stator
82
Inspecting the Cover Components
85
Refitting the Stator
87
Refitting the Flywheel Cover Components
88
Refitting the Flywheel Cover
90
Flywheel and Starting
92
Removing the Starter Motor
95
Removing the Flywheel Magneto
95
Inspecting the Flywheel Components
98
Starter Gear Rim
99
Intermediate Gear
99
Refitting the Free Wheel
100
Refitting the Intermediate Gear
101
Refitting the Flywheel Magneto
102
Refitting the Starter Motor
104
Cylinder Assy. and Timing System
104
Removing the Intake Manifold
105
Removing the Rocker-Arms Cover
105
Removing the Timing System Drive
105
Removing the Cam Shaft
108
Removing the Cylinder Head
108
Removing the Valves
110
Removing the Cylinder - Piston Assy
111
Inspecting the Small End
112
Inspecting the Wrist Pin
112
Inspecting the Piston
113
Inspecting the Piston Rings
114
Removing the Piston
114
Choosing the Gasket
115
Refitting the Piston Rings
117
Refitting the Cylinder
117
Inspecting the Cylinder Head
117
Inspecting the Timing System Components
118
Inspecting the Valve Sealings
119
Inspecting the Valve Housings
119
Inspecting the Valves
120
Inspecting the Valve Stem Guide Clearance
121
Inspecting the Springs and Half-Cones
122
Refitting the Valves
123
Inspecting the Cam Shaft
123
Refitting the Head and Timing System Components
125
Refitting the Timing Chain
132
Inspecting the Radial Air Gap
133
Refitting the Rocker-Arms Cover
135
Refitting the Intake Manifold
136
Crankcase - Crankshaft
136
Splitting the Crankcase Halves
138
Removing the Crankshaft
138
Removing the Countershaft
139
Replacing the Countershaft Bearings
140
Inspecting the Crankshaft Components
142
Inspecting the Crankshaft Alignment
143
Inspecting the Crankcase Halves
145
Inspecting the Crankshaft Plain Bearings
146
Coupling Chart
147
Countershaft
147
Refitting the Crankshaft
147
Refitting the Crankcase Halves
149
Lubrication
151
Oil Pump
152
Oil Filter
152
Conceptual Diagrams
153
General Characteristics
153
Diagnosis Guide
154
Oil Pressure Check
156
Oil Pump
157
Injection
163
Precautions
173
Terminals Setup
173
EMS Circuit Diagram
176
Troubleshooting Procedure
177
Engine Does Not Start
177
Starting Difficulties
177
Engine Stops at Idle
178
Engine Does Not Rev down
178
Exhaust Backfires in Deceleration
179
Engine Revs Irregularly
179
Poor Performance at Full Throttle
180
Engine Knocking
180
Decoder Master-Box Circuit
180
Constant Supply Circuit Check
181
Key-Switch Power Supply Circuit Check
182
Diagnostic Circuit
185
Injection Warning Light Circuit
187
Self-Diagnosis System
188
Fuel Supply System
190
Circuit Diagram
191
Removing the Injector
191
Refitting the Injector
192
Refitting the Butterfly Valve
194
Pump Supply Circuit
194
Circuit Check
195
Circuit Leak Test
198
Pressure Regulator Check
199
Fuel Pump and Filter Check
200
Resistor Check
203
Pump Consumption Check
204
Fuel Filter Check
204
Pump Bracket Overhaul
205
Pump Bracket Installation
209
Inspecting the Injector Circuit
209
Inspecting the Injector Hydraulics
213
Troubleshooting
214
Immobiliser Circuit
215
System Components
215
Virgin Circuit
216
Setting the Circuit
218
LED Signals
218
Deterring Blink
219
Checking Master-Box Data
219
Resetting the Circuit
219
Diagnostic Codes
220
Tachometer
224
Circuit Diagram
229
Inspecting the Spark Plug Shielded Cap
234
Spark Advance
235
Coolant Temperature Sensor
236
Intake Air Temperature Sensor
241
Pressure Sensor
247
Throttle Valve Opening Sensor
247
Zeroing the Throttle
252
Step Motor
254
Suspensions
260
Removing the Front Wheel
261
Front Wheel Hub Overhaul
261
Refitting the Front Wheel
263
Front Fork
264
Overhaul
264
Steering Bearing
270
Removing the Rear Wheel
272
Refitting the Rear Wheel
273
Swing-Arm
273
Shock Absorbers
282
Centre-Stand
283
Side Stand
283
Braking System
284
Rear Brake Calliper
285
Front Brake Calliper
288
Rear Brake Disc
290
Disc Inspection
291
Front Brake Disc
292
Front Brake Pads
293
Rear Brake Pads
295
Rear - Combined
296
Brake Fluid Level Check
298
Front Brake Pump
299
Cooling System
301
Circuit Diagram
302
Electric Fan Check
303
System Sealing Check
305
Coolant Replacement
305
Water Pump - Overhaul
306
Thermostat
307
Excessive System Pressure
309
Cooling Fluid Consumption
309
Oil in the Fluid
309
Chassis
310
Seat
311
Side Fairings
311
Rear Rack
311
Rear Handlebar Cover
312
Instrument Panel
313
Front Handlebar Cover
313
Headlight Assy.
313
Frame Central Cover
314
Legshield
314
Knee-Guard
315
Removing the Ignition Key-Switch When on *Off*
317
Removing the Ignition Key-Switch When on *Lock*
318
Taillight Assy.
318
Footrest
319
License Plate Holder
321
Air Filter
322
Rear Mudguard
322
Helmet Bay
323
Spoiler
323
Fuel Tank
324
Rear Central Cover
326
Front Mudguard
327
Radiator Fan
328
Pre-Delivery
329
Aesthetic Inspection
330
Tightening Torques Inspection
330
Electrical System
330
Levels Check
331
Road Test
331
Static Test
331
Functional Inspection
332
Time
333
Engine
334
Crankcase
335
Crankshaft
336
Cylinder Assy.
337
Cylinder Head Assy.
338
Rocker Arms Support Assy.
339
Cylinder Head Cover
340
Flywheel Cover
341
Driven Pulley
342
Final Gear Assy.
343
Driving Pulley
344
Transmission Cover
345
Starter Motor
346
Flywheel Magneto
347
Butterfly Valve
348
Exhaust Pipe
349
Air Cleaner
350
Frame
351
Legshield Spoiler
352
Footrests
354
Rear Cover
355
Central Cover
356
Underseat Compartment
357
Mudguard
358
Expansion Tank
360
Radiator
361
Rear Shock-Absorber
362
Steering Column Bearings
363
Handlebar Covers
364
Handlebar Components
365
Swing-Arm
366
Brake Hoses
367
Seat Lock
369
Instrument Panel
370
Rear Rack
371
Locks
372
Turn Signal Lights
373
Front Wheel
374
Rear Wheel
375
Fuel Pump
376
Electric Devices
377
Brake Callipers
380
5
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PIAGGIO BV 500 USA Specifications
General
Brand
PIAGGIO
Model
BV 500 USA
Category
Scooter
Language
English
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