BV350 Workshop Manual PDF
BV350 Workshop Manual PDF
BV350 Workshop Manual PDF
677529 - 677533
BV 350
SERVICE STATION
MANUAL
BV 350
The descriptions and images in this publication are given for illustrative purposes only and are not binding.
While the basic characteristics as described and illustrated in this booklet remain unchanged, Piaggio &
C. S.p.A. reserves the right, at any time and without being required to update this publication beforehand,
to make any changes to components, parts or 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 each
model should be checked at the official PIAGGIO sales network.
© Copyright 2012 - Piaggio & C. S.p.A. All rights reserved. Reproduction of this publication in whole or
in part is prohibited.
Piaggio & C. S.p.A. Viale Rinaldo Piaggio, 25 - 56025 PONTEDERA (PI), Italy
www.piaggio.com
SERVICE STATION MANUAL
BV 350
This service station manual has been drawn up by Piaggio & C. Spa to be used by the workshops of
Piaggio 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, no mounting work can be satisfactory if the necessary equipment and tools
are unavailable. It is therefore advisable to read the sections of this manual concerning special tools,
along with the special 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
ENGINE ENG
INJECTION INJEC
SUSPENSIONS SUSP
CHASSIS CHAS
PRE-DELIVERY PRE DE
INDEX OF TOPICS
CHARACTERISTICS CHAR
BV 350 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 well
ventilated, using special extractors if necessary; never let the engine run in an enclosed area. Exhaust
fumes are toxic.
- The battery electrolyte contains sulphuric acid. Protect your eyes, clothes and skin. Sulphuric acid is
highly corrosive; in the event of contact with your eyes or skin, rinse thoroughly with abundant water
and seek immediate medical attention.
- The battery produces hydrogen, a gas that can be highly explosive. Do not smoke and avoid sparks
or flames near the battery, especially when charging it.
- Fuel is highly flammable and it can be explosive given some conditions. Do not smoke in the working
area, and avoid naked flames or sparks.
- Clean the brake pads in a well-ventilated area, directing the jet of compressed air 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. The non original
or non-compliant spare parts 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.
- Use only equipment with metric sizes for removal, service and reassembly operations. Metric bolts,
nuts and screws are not interchangeable with coupling members using English measurements. Using
unsuitable coupling members and tools may damage the vehicle.
- When carrying out maintenance operations on the vehicle that involve the electrical system, make
sure the electrical connections have been made properly, particularly the ground and battery connec-
tions.
CHAR - 7
Characteristics BV 350
Vehicle identification
Chassis number
To read the chassis number, remove the port A in
the front case.
Engine number
The engine number «B» is stamped near the rear
left shock absorber lower support.
CHAR - 8
BV 350 Characteristics
Engine
ENGINE SPECIFICATIONS
Specification Desc./Quantity
Type Single-cylinder, 4-stroke
Engine capacity 20.18 in³ (330 cc)
Bore x stroke 3.07 × 2.72 in (78 × 69 mm)
Compression ratio 12.0±0.5
Engine idle speed 1700±100 rpm
Timing system Four valves, single overhead camshaft, chain-driven.
Valve clearance intake: 0.004 in (0.10 mm)
exhaust: 0.006 in (0.15 mm)
Max. power to the shaft 24.5 kW at 8250 rpm
MAX. torque 23.82 lb ft (32.3 Nm) at 6,250 rpm
Transmission With continuously variable transmission, torque server, V belt,
centrifugal automatic clutch in oil bath.
Final reduction gear Gear reduction unit in oil bath.
Lubrication Engine lubrication with trochoidal pump (inside the crankcase),
oil filter and pressure adjustment by-pass.
Cooling Forced coolant circulation system.
Electric Electric starter
Ignition Electronic, inductive, high efficiency ignition, integrated with the
injection system, with variable advance and separate H.V. coil.
Ignition advance Three-dimensional map managed by control unit
Fuel system IAWM3G electronic injection with 1.50 Ø (38 mm) diameter
throttle body, electric fuel pump.
Spark plug NGK CR7EKB
Fuel Unleaded petrol 90 (M+R) /2 minimum octane
Silencer Absorption-type exhaust silencer with a three-way catalytic
converter and lambda probe to the exhaust.
Emissions compliance EURO 3
Transmission
TRANSMISSION
Specification Desc./Quantity
Transmission With continuously variable transmission, torque server, V belt,
centrifugal automatic clutch in oil bath.
Final reduction Gear reduction unit in oil bath.
Capacities
CAPACITY
Specification Desc./Quantity
Engine oil approx. 0.39 USgal (0.33 UKgal) (1.5 l)
Transmission oil approx. 0.13 USgal (0.11 UKgal) (500 cc)
Fuel tank capacity 3.43 ± 0.26 USgal (2.86 ± 0.22 UKgal) (13 ± 1 l)
Cooling system fluid 0.38 USgal (0.46 gal) (1.75 l)
CHAR - 9
Characteristics BV 350
Electrical system
ELECTRICAL SYSTEM
Specification Desc./Quantity
Electric Electric starter
Ignition Electronic, inductive, high efficiency ignition, integrated with the
injection system, with variable advance and separate H.V. coil.
Ignition advance Three-dimensional map managed by control unit
Spark plug NGK CR7EKB
Alternative spark plug -
Battery 12V-12Ah
Generator alternating current
Brakes
BRAKES
Specification Desc./Quantity
Front brake Ø 11.81 (300 mm) disc brake with hydraulic control activated
by handlebar right-side lever.
Integral brake Ø 9.45 (240 mm) Rear disc brake with hydraulic control acti-
vated by handlebar right-side lever; the front disc is served by
a pressure filler valve.
Tightening Torques
BODYWORK
Name Torque in Nm
Fixing screws closing the front headlamp cover (0.73÷1.25) lb ft (1÷1.7) Nm
CHAR - 10
BV 350 Characteristics
Name Torque in Nm
Instrument panel fixing screws (0.73÷1.25) lb ft (1÷1.7) Nm
Front cover - rear cover fixing screws (0.73÷1.25)lb ft (1÷1.7)Nm
Handlebar cover fixing screws (0.73÷1.25)lb ft (1÷1.7)Nm
Headlight lower fixing screws (1.47÷2.95)lb ft (2÷4)Nm
Headlight upper fixing screws (1.47÷2.95)lb ft (2÷4)Nm
Forks cover side fixing screws (0.73÷1.45)lb ft (1÷2)Nm
Front upper mudguard side fixing nuts (2.95÷4.79)lb ft (4÷6.5)Nm
Forks cover rear fixing screws (3.31÷5.16)lb ft (4.5÷7)Nm
FRONT BRAKE
Name Torque in Nm
Brake fluid pump-hose fitting (11.08÷14.75)lb ft (16÷20)Nm
Bearing lock screw (6.64÷8.11)lb ft (9÷11)Nm
Oil bleed screw (8.85÷11.80)lb ft (12÷16)Nm
Pad fastening pin (14.45÷18.07)lb ft (19.6÷24.5)Nm
Screw tightening calliper to support (17.70÷19.91)lb ft (24÷27)Nm
Brake disc screws (5.90÷7.73)lb ft (8÷10)Nm
Brake fluid pipe-calliper fitting (14.75÷18.43)lb ft (20÷25)Nm
Screws fixing the distribution mechanism (7.73÷8.11)lb ft (10÷11)Nm
Front calliper pipe tightening - distribution mechanism (14.75÷18.43)lb ft (20÷25)Nm
Brake pipes fixing screw at the distribution mechanism (14.75÷18.43)lb ft (20÷25)Nm
Front pump pipe grommet screw - clamp (7.73÷8.11)lb ft (10÷11)Nm
Distribution mechanism pipe screw - front brake pump (14.75÷18.43)lb ft (20 ÷ 25)Nm
REAR BRAKE
Name Torque in Nm
Rear brake calliper-pipe fitting (14.75÷18.43)lb ft (20÷25)Nm
Rigid / flexible pipe fitting (9.58÷13.27)lb ft (13÷18)Nm
Rear brake pump-pipe fitting (11.80÷14.75)lb ft (16÷20)Nm
Rear brake fixing screws (14.75÷18.43)lb ft (20÷25)Nm
Brake disc screws (5.90÷7.73)lb ft (8÷10)Nm
Pad fastening pin (14.45÷18.07)lb ft (19.6÷24.5)Nm
Brake pump fixing screw (30.97÷37.61)lb ft (42÷51)Nm
Pipe grommet fixing brake valve screw - rear calliper (7.37÷8.11)lb ft (10÷11)Nm
Pipe grommet fixing brake valve screw - rear calliper (7.37÷8.11)lb ft (10÷11)Nm
ELECTRICAL SYSTEM
Name Torque in Nm
Side stand sensor fixing screws (3.68÷5.16)lb ft (5÷7)Nm
Locking the spark plug (7.37÷8.85)lb ft (10÷12)Nm
Rear wheel engine speed sensor tightening screw (5.16÷7.37)lb ft (7÷10)Nm
SILENCER
Name Torque in Nm
Silencer heat guard fixing screw (2.95÷3.68)lb ft (4÷5)Nm
Screw for fixing silencer to supporting arm (14.75÷18.43)lb ft (20÷25)Nm
Lambda probe tightening on exhaust manifold (29.50÷36.87)lb ft (40÷50)Nm
Exhaust manifold-silencer clamp tightening (8.85÷9.58)lb ft (12÷13)Nm
Nuts fixing the exhaust manifold to the head (11.80÷13.27)lb ft (16÷18)Nm
Joint pipe (Setting load 440.92-1322.77 lb - LOCTITE 603) (Setting load
200-600 Kg - LOCTITE 603)
FLYWHEEL
Name Torque in Nm
Flywheel cover screw (8.11÷9.59)lb ft (11÷13)Nm
Flywheel fixing nut (73.76÷81.13)lb ft (100÷110)Nm
Screw fixing freewheel to flywheel (9.59÷11.06)lb ft (13÷15)Nm
Starter sprocket check fixing screw (3.68÷4.42)lb ft(5÷6)Nm
Starter motor fixing screws (8.11÷9.58)lb ft (11÷13)Nm
Starter crown plate fixing screws (3.69÷4.42)lb ft (5÷6)Nm
CHAR - 11
Characteristics BV 350
FLYWHEEL COVER
Name Torque in Nm
Pick-up screws (2.21÷2.95)lb ft (3÷4)Nm
Stator fixing screws (5.90÷7.38)lb ft (8÷10)Nm
Stator cable plates clamping screws (2.21÷2.95)lb ft (3÷4)Nm
Oil drain screw (14.75÷17.70)lb ft (20÷24)Nm
Flywheel cover retainer screws (2 screws) - PRETIGHTENING (3.69÷4.42)lb ft (5÷6)Nm
Flywheel cover retainer screws (12 screws) - TIGHTENING (8.11÷9.59)lb ft (11÷13)Nm
TCEI M6x25 flywheel side cover retainer screw (5.9 ÷ 7.37) lb ft (8 ÷ 10) Nm
TCIC M5x10 flywheel cover retainer screw (2.21 ÷ 2.95) lb ft (3 ÷ 4) Nm
Fixing clamps of head pump cover by-pass pipe (0.96÷1.25)lb ft (1.3÷1.7)Nm
Water pump cover fixing screw M5 (2.21÷2.95)lb ft (3÷4)Nm
Water pump cover fixing screw M6 (8.11÷9.59)lb ft (11÷13)Nm
Impeller on the pump shaft (2.95÷4.42)lb ft (4÷6)Nm
Water pump impeller cover screws (2.21÷2.95)lb ft (3÷4)Nm
Water pump impeller driving link (9.59÷11.06)lb ft (13÷15)Nm
Coil fixing screw (8.11÷9.59)lb ft (11÷13)Nm
CRANKCASE
Name Torque in Nm
Calibrated fixing dowel (3.69÷5.16)lb ft (5÷7)Nm
Bearing lock screw (6.64÷8.11)lb ft (9÷11)Nm
Oil filter cover (17.70÷22.13)lb ft (24÷30)Nm
Oil pump command sprocket screw (6.64÷8.11)lb ft (9 ÷11)Nm
Oil pump chain slider locking screws (3.69÷4.42)lb ft (5÷6)Nm
Engine oil level shaft (0.95÷1.25)lb ft (1.3÷1.7)Nm
Engine-crankcase coupling screws (8.11÷9.59)lb ft (11÷13)Nm
CHAR - 12
BV 350 Characteristics
Name Torque in Nm
M12x1.25 gear clutch shaft retainer nut (70.07÷77.44)lb ft (95÷105)Nm
Oil relief screw (11.06÷12.54)lb ft (15÷17)Nm
Reduction unit oil drainage screw (11.06÷12.54)lb ft (15÷17)Nm
Bearing lock screw (6.64÷8.11)lb ft (9÷11)Nm
Clutch output shaft nut (88.51 ÷ 95.88) lb ft (120 ÷ 130) Nm
Driven pulley nut (36.88 ÷ 44.25) lb ft (50 ÷ 60) Nm
FRONT SUSPENSION
Name Torque in Nm
Front wheel axle (33.19÷36.88)lb ft (45÷50)Nm
Calliper mounting bracket screw 7.37 lb ft (10Nm) (Tighten after inserting the front wheel axle)
Check that there is no breakage.
front mudguard to plate fixing screw (3.32÷5.16)lb ft (4.5÷7)Nm
Fixing screw for mudguard plate to fork (6.64÷8.11)lb ft (9÷11)Nm
Stem support clamp tightening screws Apply a torque of (18.44÷25.08)lb ft (25÷34)Nm to the lower
screw «1» Lock the upper screw «2» to a torque of
(18.44÷25.08)lb ft (25÷34)Nm Lock the lower screw «1» to a
torque of (18.44÷25.08)lb ft (25÷34)Nm
Fork locking screws cap (11.06÷22.13)lb ft (15÷30)Nm
Hydraulic rod fixing screw (18.44÷25.81*)lb ft (25÷35*)Nm
REAR SUSPENSION
Name Torque in Nm
Rear wheel axle (76.71÷92.93)lb ft (104÷126)Nm
Fixing screw for wheel rim to hub (25.08÷28.03)lb ft (34÷38)Nm
Shock absorber lower clamping (23.97÷29.13)lb ft (32.5÷39.5)Nm
Silencer supporting arm to engine screws (*) (14.75÷18.44)lb ft (20÷25)Nm
Upper shock absorber fixing - self locking nut M10 (29.50÷32.45)lb ft (40÷44)Nm
Shock absorber mounting bracket fixing (14.75÷17.70)lb ft (20÷24)Nm
M16x13 wheel retaining nut (75.23÷91.46)lb ft (102÷124)Nm
STEERING
Name Torque in Nm
Handlebar fixing screw (36.88÷40.57)lb ft (50÷55)Nm
Fixing screws for the handlebar control unit U-bolts (5.16÷7.38)lb ft (7÷10)Nm
Steering tube upper ring nut (29.50÷33.19)lb ft (40÷45)Nm
Steering tube lower ring nut (10.33÷12.54)lb ft (14÷17)Nm
Throttle grip cables right control fastener screw (2.21÷2.95)lb ft (3÷4)Nm
Hand grip counterweight retainer screw (6.64÷8.11)lb ft (9÷11)Nm
Mirrors fastening long nut (14.75÷18.44)lb ft (20÷25)Nm
Rear flange fastening screw (0.37÷0.59)lb ft (0.5÷0.8)Nm
CHASSIS
Name Torque in Nm
Centre stand bolt (29.50÷33.19)lb ft (40÷45)Nm
Side stand fixing bolt (29.50÷33.19)lb ft (40÷45)Nm
Throttle cable pipe grommet screw (7.38÷8.11)lb ft (10÷11)Nm
Clip / pipe grommet fastening screw (7.38÷8.11)lb ft (10÷11)Nm
SWINGING ARM
Name Torque in Nm
Self-locking retainer nut M10 upper pin (left side) (50.15÷55.32)lb ft (68÷75)Nm
Self-locking retainer nut M10 bottom lower silent block support (36.88÷40.57)lb ft (50÷55)Nm
bracket
Self-locking retainer nut M10 pin (right side) (30.24÷33.19)lb ft (41÷45)Nm
Self-locking retainer nut M10 motor attachment (right side) (40.57÷44.25)lb ft (55÷60)Nm
Retainer nut of silent block support bracket (left side) (65.64÷79.66)lb ft (89÷108)Nm
Lower pin bushing (3.76÷5.09)lb ft (5.1÷6.9)Nm
CHAR - 13
Characteristics BV 350
LUBRICATION
Name Torque in Nm
Crankcase timing cover screws (8.11÷9.59)lb ft (11÷13)Nm
Screw fixing oil pump to the crankcase (3.69÷4.43)lb ft (5÷6)Nm
Pump rod screw (9.59÷11.06)lb ft (13÷15)Nm
Minimum oil pressure sensor locking (8.85÷10.33)lb ft (12÷14)Nm (LOCTITE 5091 Edge closure be-
tween metal body and plastic block)
Overhaul data
Assembly clearances
CYLINDER - PISTON
Specification Desc./Quantity
Piston diameter (ØP) 3.0695±0.00059 in (77.967±0.014 mm)
Piston diameter (ØC) 3.0708(+0.0015 +0.0004)in (78(+0.038 +0.01)mm)
COUPLING CATEGORIES
Name Initials Cylinder Piston Play on fitting
cylinder-piston M (3.071251÷3.071526)in (3.069006÷3.069282)in (0.001969÷0.002519)in
(78.010÷78.017)mm (77.953÷77.960)mm (0.050 ÷ 0.064)mm
cylinder-piston N (3.071526÷3.071802)in (3.069282÷3.069558)in (0.001969÷0.002519)in
(78.017÷78.024)mm (77.960 ÷ 77.967)mm (0.050 ÷ 0.064)mm
cylinder-piston O (3.071802÷3.072077)in (3.069558÷3.069833)in (0.001969÷0.002519)in
(78.024÷78.031)mm (77.967÷77.974)mm (0.050 ÷ 0.064)mm
cylinder-piston P (3.072077÷3.072353)in (3.069833÷3.070109)in (0.001969÷0.002519)in
(78.031÷78.038)mm (77.974 ÷ 77.981)mm (0.050 ÷ 0.064)mm
N.B.
THE PISTON MUST BE INSTALLED WITH THE ARROW FACING TOWARDS THE EXHAUST SIDE,
THE PISTON RINGS MUST BE INSTALLED WITH THE WORD «TOP» OR THE STAMPED MARK
FACING UPWARDS.
CHAR - 14
BV 350 Characteristics
Characteristic
Pin external diameter
0.66929(+0 -0.000157)in (17.000 (+0 -0.004))mm
Characteristic
Standard diameter
0.66929(+0.00024 +0.000039)in (17(+0.006
+0.001)mm)
CHAR - 15
Characteristics BV 350
Characteristic
Maximum allowable run-out:
0.001 over 0.05 mm
CRANKSHAFT
Titolo Durata/Valore Testo Breve (< 4000 car.) Indirizzo Immagine
Crankshaft Axial clearance between
crankshaft and connecting rod
Axial clearance between crankshaft and connecting rod
CHAR - 16
BV 350 Characteristics
CHAR - 17
Characteristics BV 350
CRANKSHAFT
Specification Desc./Quantity
Crankshaft bearings: Standard diameter: Cat. 1 (1.4174÷1.4176)in (36.003÷36.009)mm
Crankshaft bearings: Standard diameter: Cat. 2 (1.4176÷1.4179)in (36.009÷36.015)mm
CHAR - 18
BV 350 Characteristics
CHAR - 19
Characteristics BV 350
Characteristic
Crankshaft-crankcase axial clearance (H)
(0.005÷0.016)in (0.15 ÷ 0.43)mm
Characteristic
Standard diameter (with fitted bushing)
Ø0.006(+0.0005 +0.0009)in Ø17(+0.015 +0.025)
mm
- To obtain a good bushing lubrication it is necessary to have both an optimal lubricating pressure and
a good oil flow rate; the bushings must be correctly positioned so as not to obstruct the oil supply
channels.
Characteristic
«A»
AXIS CYLINDER
CHAR - 20
BV 350 Characteristics
Characteristic
«A»
AXIS CYLINDER
BUSHINGS
TYPE IDENTIFICATION CRANKSHAFT HALF-BEARING
B BLUE (0.0775÷0.0777)in (1.970÷1.974)mm
C YELLOW (0.0777÷0.0778)in (1.974÷1.978)mm
E GREEN (0.0778÷0.0780)in (1.978÷1.982)mm
CHAR - 21
Characteristics BV 350
Characteristic
«A»
AXIS CYLINDER
- After measuring the crankshaft, check the maximum clearance allowed.
Characteristic
Crankshaft-bushing maximum clearance admitted:
(0.003)in (0.08)mm
- The bushings housing hole in the crankcase half is divided into two categories depending on the size,
Category 1 and Category 2.
- Combine the shaft with two category 1 crankwebs 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.
CHAR - 22
BV 350 Characteristics
- According to the classification of the shaft CAT.1 - CAT.2 combine a complete crankcase pre-fitted
with suitable bushings according to the starting shaft.
CATEGORIES
CRANKCASE HALVES ENGINE HALF-SHAFT BUSHING
Cat. 1 Cat. 1 C
Cat. 2 Cat. 2 C
Cat. 1 Cat. 2 B
Cat. 2 Cat. 1 E
Characteristic
Crankshaft category:
CAT. 1 - CAT. 2
Cylinder Head
Before performing head service operations, thoroughly clean all coupling surfaces. Note the position of
the springs and the valves so as not to change the original position during refitting
- Using a trued bar and a feeler gauge check that the cylinder head surface is not worn or distorted.
Characteristic
Maximum allowable run-out:
0.001 over 0.05 mm
CHAR - 23
Characteristics BV 350
CHAR - 24
BV 350 Characteristics
HEAD BEARINGS
Specification Desc./Quantity
bearing «A» Ø(0.511÷0.512)in Ø(13.000÷13.018)mm
bearing «B» Ø(0.787÷0.788)in Ø(20.000÷20.021)mm
bearing «C» Ø(1.456÷1.457)in Ø(37.000÷37.025)mm
Characteristic
Standard length
(1.602)in (40.7)mm
Allowable limit after use:
(1.543)in (39.2)mm
Characteristic
Standard value:
(0.039÷0.051)in (1 ÷ 1.3)mm
Admissible limit:
(0.062)in (1.6)mm
- If the width of the mark on the valve seat is larger than the prescribed limits, true the seats with a 45°
milling cutter and then grind.
- In case of excessive wear or damage, replace the head.
STANDARD DIAMETER
Specification Desc./Quantity
Intake: (0.1951÷0.1957)in (4.957÷4.972)mm
Exhaust: (0.1942÷0.1948)in (4.935÷4.950)mm
CHAR - 25
Characteristics BV 350
Characteristic
Admissible limit:
(0.0007)in (0.02)mm
Characteristic
Admissible limit:
(0.007)in (0.2)mm
Characteristic
Valve guide:
0.196(+0 +0.0004)in 5(+0 +0.012)mm
CHAR - 26
BV 350 Characteristics
INTAKE
Specification Desc./Quantity
Standard clearance: (0.001÷0.002)in (0.028÷0.055)mm
Admissible limit: (0.003)in (0.08)mm
EXHAUST
Specification Desc./Quantity
Standard clearance: (0.001÷0.003)in (0.05÷0.077)mm
Admissible limit: (0.003)in (0.1)mm
- Check that there are no signs of wear on the mating surface with the set screw articulated terminal.
STANDARD DIAMETER
Specification Desc./Quantity
Camshaft check: Standard diameter Bearing A Ø: (1.454÷1.455)in (36.95÷36.975)mm
Camshaft check: Standard diameter Bearing B diameter: (0.785÷0.786)in (19.959÷19.98)mm
CHAR - 27
Characteristics BV 350
STANDARD HEIGHT
Specification Desc./Quantity
Camshaft check: Wear limit Exhaust: (1.178)in (29.945)mm
Camshaft check: Wear limit Intake: (1.218)in (30.948)mm
Camshaft check: Standard height Intake: (1.220±0.001)in (31.008±0.03)mm
Camshaft check: Standard height Exhaust: (1.181±0.001)in (30.005±0.03)mm
CHAR - 28
BV 350 Characteristics
CHAR - 29
Characteristics BV 350
Characteristic
Compression ratio
(11.7÷12.3) : 1
Measurement "A" to be taken is a value of piston re-entry, it indicates by how much the plane formed
by the piston crown falls below the plane formed by the top of the cylinder. The further the piston falls
inside the cylinder, the less the base gasket to be applied (to recover the compression ratio) and vice
versa.
N.B.
MEASUREMENT "A" MUST BE TAKEN WITHOUT ANY GASKET FITTED BETWEEN THE CRANK-
CASE AND CYLINDER AND AFTER RESETTING THE DIAL GAUGE, EQUIPPED WITH A SUP-
PORT, ON A GROUND PLANE
CHAR - 30
BV 350 Characteristics
Products
CHAR - 31
INDEX OF TOPICS
TOOLING TOOL
BV 350 Tooling
SPECIFIC TOOLS
Stores code Description
001330Y Tool for fitting steering seats
001467Y005 Screw
TOOL - 33
Tooling BV 350
TOOL - 34
BV 350 Tooling
020115Y Ø 18 punch
TOOL - 35
Tooling BV 350
TOOL - 36
BV 350 Tooling
TOOL - 37
Tooling BV 350
020375Y 28 x 30 mm adaptor
TOOL - 38
BV 350 Tooling
TOOL - 39
Tooling BV 350
020444Y009 wrench 46 x 55
TOOL - 40
BV 350 Tooling
020477Y 37 mm adaptor
TOOL - 41
Tooling BV 350
TOOL - 42
BV 350 Tooling
TOOL - 43
Tooling BV 350
TOOL - 44
INDEX OF TOPICS
MAINTENANCE MAIN
Maintenance BV 350
Maintenance chart
MAIN - 46
BV 350 Maintenance
Spark plug
Proceed as follows:
- Remove the case that grants access to the spark
plug located on the right side fairing by unscrewing
the indicated screw.
- Disconnect cap «A» from the spark plug HV ca-
ble by turning it clockwise until releasing it from the
retainer.
- Unscrew the spark plug using the wrench sup-
plied.
- When refitting, place the spark plug into the hole
at the corresponding angle and finger tighten it as
far as it will go. Use the wrench only to tighten it.
- Place cap «A» fully over the spark plug, making
sure it is in the retainer again.
WARNING
Characteristic
Spark plug
NGK CR7EKB
Hub oil
MAIN - 47
Maintenance BV 350
Check
Check the oil in the rear hub. To check the rear hub
oil level, proceed as follows:
1. Rest the vehicle onto its centre stand, on level
ground.
2. Unscrew the screw «A» and if oil comes out or
touches the screw hole the level is correct. Other-
wise, top up the oil.
3. Screw the screw back in, checking that it is
locked in place.
CAUTION
Recommended products
AGIP GEAR SAE 80W-90 Lubricant for gear-
boxes and transmissions.
API GL-4
Characteristic
Transmission oil
approx. 0.13 USgal (0.11 UKgal) (500 cc)
MAIN - 48
BV 350 Maintenance
Air filter
Recommended products
AGIP FILTER OIL Special product for the treat-
ment of foam filters.
-
MAIN - 49
Maintenance BV 350
Engine oil
Replacement
Recommended products
eni i-Ride scooter 15W-50 Synthetic-based lu-
bricant for four stroke engines.
JASO MA, MA2 - API SJ - ACEA A3
Characteristic
Engine oil
approx. 0.39 USgal (0.33 UKgal) (1.5 l)
MAIN - 50
BV 350 Maintenance
Check
The oil filter must be replaced every time the oil is changed.
Use new oil of the recommended type for topping up and changing purposes and comply with the
regulations regarding timing and mileage, as described in the periodic maintenance table.
Make sure the pre-filter and drainage plug O-rings are in good conditions.
Lubricate them and refit the mesh filter and the oil drainage plug, screwing them up to the prescribed
torque. Refit the new oil filter being careful to lubricate the O-ring before fitting it.
Change the engine oil.
WARNING
MAIN - 51
Maintenance BV 350
- If values are found that are not in compliance, proceed with the adjustment of the valve clearance, as
described under "Engine/Fitting the head and timing system components."
Characteristic
Valve clearance
intake: 0.004 in (0.10 mm)
exhaust: 0.006 in (0.15 mm)
See also
Footrest
Helmet bay
Inspecting the valves
MAIN - 52
BV 350 Maintenance
Cooling system
Level check
MAIN - 53
Maintenance BV 350
Recommended products
AGIP PERMANENT SPECIAL Ethylene glycol-
based antifreeze fluid with organic inhibition
additives. Red, ready to use.
ASTM D 3306 - ASTM D 4656 - ASTM D 4985 -
CUNA NC 956-16
Braking system
Level check
Top-up
- Remove the front handlebar cover in advance and move the rear handlebar cover.
Recommended products
MAIN - 54
BV 350 Maintenance
See also
Front handlebar cover
Rear handlebar cover
Headlight adjustment
Proceed as follows:
1. Position the vehicle in running order and with
the tyres inflated to the prescribed pressure, onto
a flat surface 32.8 ft (10 m) away from a half-lit
white screen; ensure that the longitudinal axis of
the vehicle is perpendicular to the screen;
2. Turn on the headlight and check that the boun-
dary of the light beam projected onto the screen is
not higher than 9/10 or lower than 7/10 of the dis-
tance between the centre of the headlight and the
ground;
3. Otherwise, loosen the screws fixing the projec-
tor to the support and adjust the direction.
N.B.
THE ABOVE PROCEDURE COMPLIES WITH THE EURO-
PEAN STANDARDS REGARDING MAXIMUM AND MINI-
MUM HEIGHT OF LIGHT BEAMS. REFER TO THE STATU-
TORY REGULATIONS IN FORCE IN EVERY COUNTRY
WHERE THE VEHICLE IS USED.
MAIN - 55
Maintenance BV 350
Anti-evaporation system
MAIN - 56
BV 350 Maintenance
CANISTER
- Release the flexible retainer strap.
- Release the clamps and by pulling out the pipes,
remove the canister.
ROLL-OVER VALVE
- Release the canister flexible retainer strap and
removing the two metal clamp, pull out the pipes.
- Remove the roll-over valve by pulling it out from
the support.
MAIN - 57
Maintenance BV 350
SAFETY VALVE
- Remove the two metal clamps and remove the
pipes.
- Remove the safety valve.
Canister inspection
The canister is essential to treat the hydrocarbons present in the volume of gas that escapes from the
tank when there is an increase in internal pressure (tank heating induced by the cooling radiator, by the
motor or by the external environment).
The volume of air is limited by the operation of the ventilation valve (Roll-over).
Although the amount of hydrocarbons coming from the tank is small enough to avoid the saturation of
the canister, it is necessary to regenerate the activated carbon by means of a reversed flow of ambient
air sucked by the engine.
These vacuum of pollution and carbon regeneration take place at each cycle of use of the vehicle.
MAIN - 58
BV 350 Maintenance
The cleaning of the canister is achieved via a controlled flow of air from the vacuum socket in the intake
manifold.
To ensure that the engine works properly, it is necessary that the flow of air is not too intense, this is
achieved by means of a restricted section 0.0354in (0.9 mm) formed in the socket on the intake manifold.
The relative connecting pipe with the canister, includes the installation of the safety valve.
This is a one-way valve which ensures the passage of air in the direction of the manifold when the
control vacuum is greater than 2.9PSI (20kPa) (200mbar).
The vacuum of the engine at idle, causes a slight flow of air easily compensated by the idle speed
adjustment parameters.
When the vehicle is stopped, the safety valve will be closed due to the lack of control vacuum therefore,
any expansion of the fuel tank, will not cause pollution of the intake manifold, and then cause flooding
of the engine.
Characteristic
Standard opening vacuum
MAIN - 59
Maintenance BV 350
• Aeration of the tank while riding (the ambient air enters the tank in relation to the volume of
fuel used).
• Pressurisation of the tank (while riding or during a break, you may experience increases in
the temperature inside the tank. The valve must pressurize the tank to limit the escape of
fuel vapour to the canister).
• Prevent pollution of the canister with the liquid fuel (in case of fall of the vehicle, the valve
must block the connection with the canister).
MAIN - 60
BV 350 Maintenance
MAIN - 61
INDEX OF TOPICS
TROUBLESHOOTING TROUBL
BV 350 Troubleshooting
This section makes it possible to find what solutions to apply when troubleshooting.
For each failure, a list of the possible causes and pertaining operations is given.
Engine
Poor performance
POOR PERFORMANCE
Possible Cause Operation
Fuel pump Check the injection load solenoid
Excess of scales in the combustion chamber Descale the cylinder, the piston, the head and the valves
Incorrect timing or worn timing system elements Time the system again or replace the worn parts
Obstructed muffler Replace
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.
Oil level exceeds maximum Check for causes and fill to reach the correct level
Lack of compression: parts, cylinder and valves worn Replace the worn parts
Drive belt worn Replace
Inefficient automatic transmission 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.
Clutch slipping Check the clutch system and/or the bell and replace if neces-
sary
Overheated valves Remove the head and the valves, grind or replace the valves
Wrong valve adjustment Adjust the valve clearance properly
Valve seat distorted Replace the head unit
Starting difficulties
DIFFICULT STARTING
Possible Cause Operation
Rpm too low at start-up or engine and start-up system dam- Check the starter motor, the system and the torque limiter
aged
Incorrect valve sealing or valve adjustment Inspect the head and/or restore the correct clearance
Engine flooded 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 engine 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.
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
Flat battery 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 tight-
ened
EXCESSIVE CONSUMPTION
Possible Cause Operation
Wrong valve adjustment Adjust the valve clearance properly
Overheated valves Remove the head and the valves, grind or replace the valves
TROUBL - 63
Troubleshooting BV 350
TROUBL - 64
BV 350 Troubleshooting
Insufficient braking
Brakes overheating
BRAKES OVERHEATING
Possible Cause Operation
Defective plunger sliding Replace the calliper.
Brake disc slack or distorted Check the brake disc screws are locked; use a dial gauge and
a wheel mounted on the vehicle to measure the axial deviation
of the disc.
Clogged compensation holes on the pump Clean carefully and blast with compressed air
Swollen or stuck rubber gaskets Replace the calliper.
Heavy steering
STEERING HARDENING
Possible Cause Operation
Steering hardening Check the tightening of the top and bottom ring nuts. If irregu-
larities continue in turning the steering even after making the
above adjustments, check the rotation seats and the steering
fifth wheels.
Noisy suspension
NOISY SUSPENSION
Possible Cause Operation
Faults in the suspension system If the front suspension is noisy, check: tightening torques,
headstock components, inspect forks.
TROUBL - 65
Troubleshooting BV 350
TROUBL - 66
INDEX OF TOPICS
Components arrangement
ELE SYS - 68
BV 350 Electrical system
ELE SYS - 69
Electrical system BV 350
ELE SYS - 70
BV 350 Electrical system
Ground points
ELE SYS - 71
Electrical system BV 350
Instrument panel
ELE SYS - 72
BV 350 Electrical system
M = Digital display
Front side
ELE SYS - 73
Electrical system BV 350
ELE SYS - 74
BV 350 Electrical system
ELE SYS - 75
Electrical system BV 350
1. Immobilizer antenna
ELE SYS - 76
BV 350 Electrical system
ELE SYS - 77
Electrical system BV 350
ELE SYS - 78
BV 350 Electrical system
7. At instrument panel
8. At headlight
9. At left stop button
10. At right stop button
Back side
ELE SYS - 79
Electrical system BV 350
1. Starter relay
2. To the fuse holder terminal block
3. Battery positive
4. To the starter relay
5. Ground point
6. Starter motor positive cable
7. Saddle opening actuator
ELE SYS - 80
BV 350 Electrical system
ELE SYS - 81
Electrical system BV 350
Conceptual diagrams
ELE SYS - 82
BV 350 Electrical system
7.F06-5A
8.Starter relay
9.Starter motor
10.12V - 10 Ah Battery
11.Chassis ground
12. Regulator
13. Flywheel
14. Antitheft
15. Actuator control receiver pre-installation
16.Antitheft
17.Reset receiver radio
18.Saddle button
19.Actuator
20.LV socket
21.Helmet compartment light button
22.Light unit
23.Rear right turn indicator
24.Rear left turn indicator
25.Front right turn indicator
26.Front left turn indicator
27.Antitheft
28.Turn indicator warning light
29.Turn indicator switch
30. turn indicator control
31.Low beam bulb
32.High beam bulb
33.High beam warning light
34.Light switch
35.Headlight relay
36.Electronic control unit
37.Instrument panel
38.Fuel gauge
39.Engine temperature sensor
40.Ambient temperature sensor
41.Speed sensor
42.Mode button
43.Electric fan
44.Immobilizer antenna
ELE SYS - 83
Electrical system BV 350
ELE SYS - 84
BV 350 Electrical system
Ignition
ELE SYS - 85
Electrical system BV 350
ELE SYS - 86
BV 350 Electrical system
ELE SYS - 87
Electrical system BV 350
ELE SYS - 88
BV 350 Electrical system
16.Antitheft
17.Reset receiver radio
18.Saddle button
19.Actuator
20.LV socket
21.Helmet compartment light button
22.Light unit
36.Electrical control unit
37.Instrument panel
40.Ambient temperature sensor
41.Speed sensor
42.Mode button
43.Electric fan
45.Electric fan relay
52.Horn
53.Horn button
58.Injection load solenoid
59.Fuel pump
64.Diagnostics socket
66.Roll-over sensor
ELE SYS - 89
Electrical system BV 350
ELE SYS - 90
BV 350 Electrical system
Immobiliser
The electronic ignition system is controlled by the control unit with the integrated Immobilizer system.
The immobiliser is an antitheft system which allows the vehicle to function only if it is activated by means
of the coded keys that the control unit recognises. The code is integrated in a transponder in the key
block. This allows the driver clear operation without having to do anything other than just turning the
key. The Immobilizer system consists of the following components:
- an electronic control unit
- immobilizer antenna
- master key with built-in transponder
- service key with built-in transponder
- diagnosis LED
The diagnosis LED also works as a theft-deterrent blinker. This function is activated every time the key
switch is set to «OFF» 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. 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 programming of the electronic control unit If the LED is off regard-
less of the position of the ignition switch and/or the instrument panel is not initiated, check if:
- there is battery voltage
- fuses 1, 3, 4, 6 are in working order
- there is power to the control unit as specified below:
ELE SYS - 91
Electrical system BV 350
ELE SYS - 92
BV 350 Electrical system
With the ignition switch at «ON» check if there is battery voltage between the Orange-Blue and Black
cables.
Virgin circuit
When the ignition system is not encrypted, any key will start the engine but limited to 2000 rpm. The
keys can only be recognised if the control unit has been programmed properly. The data storage pro-
cedure for a previously not programmed control unit provides for the recognition of the Master as the
first key to be stored to memory: this becomes particularly important because it is the only key that
enables the control unit to be wiped clean and reprogrammed for the memorisation of the service keys.
The Master and service keys must be used to code the system as follows:
- Insert the Master key, turn it to «ON» and keep this position for two seconds (lower and upper limits
1 to 3 seconds).
- Insert the service key and turn it to «ON» for 2 seconds.
ELE SYS - 93
Electrical system BV 350
- If you have copies of the key, repeat the operation with each key.
- 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.
It is essential to adhere to the times and the procedure. If you do not, start again from the beginning.
Once the system has been programmed, the Master key transponder is strictly matched with the control
unit. With this link established, it is now possible to encode new service keys, in the event of losses,
replacements, etc. Each new programming deletes the previous one; to add or delete a key it is therefore
necessary to repeat the procedure using all the keys that you intend to keep in use. If a service key
becomes uncoded, the efficiency of the high voltage circuit shielding must be thoroughly inspected: In
any case it is advisable to use resistor spark plugs.
Diagnostic codes
ELE SYS - 94
BV 350 Electrical system
5. Programmed control unit - fault detected: a light code is displayed according to the fault detected,
after which the LED remains on steadily. The engine cannot be started. The codes that can be trans-
mitted are:
- 1-flash code
- 2-flash code
- 3-flash code
ELE SYS - 95
Electrical system BV 350
Ignition circuit
No spark plug
WARNING
ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS
DISCONNECTED.
HV coil primary resistance value:
Disconnect the connector of the HV coil and meas-
ure the resistance between the two terminals.
Characteristic
HV coil resistance primary value:
~ 670 m Ω ± 10%
ELE SYS - 96
BV 350 Electrical system
The charging circuit consists of three-phase alternator and a permanent magneto flywheel.
The generator is directly connected to the voltage regulator.
This, in its turn, is connected directly to the ground and the battery positive terminal passing through
the 30A protective fuse.
The three-phase alternator provides good recharge power and at low revs a good compromise is ach-
ieved between generated power and idle stability.
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
ELE SYS - 97
Electrical system BV 350
STARTER BUTTON
LIGHT SWITCH
HORN BUTTON
ELE SYS - 98
BV 350 Electrical system
MODE BUTTON
STAND BUTTON
ELE SYS - 99
Electrical system BV 350
STOP BUTTONS
Stator check
Electric characteristic
Resistance:
0.2 to 1 Ω
Characteristic
Voltage
14 ÷ 15V at 5,000 rpm with lights off
Characteristic
Voltage
14 ÷ 15V at 5,000 rpm with lights off
VOLTAGE REGULATOR/RECTIFIER
Specification Desc./Quantity
Type Non-adjustable three-phase transistor
Voltage 14 ÷ 15V at 5,000 rpm with lights off
Starter motor
KEY
1. Starter motor
2. Starter relay
3. Battery
4. Fuse No. 1
5. Ignition switch contacts
6. Fuse No. 5
7. Stop buttons
8. Starter button
9. Injection ECU
WARNING
ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS
DISCONNECTED.
1) Check if there is continuity of the Red cable connecting the battery, the start-up solenoid and the
starter motor.
2) Check fuses No. 1 and 5, the ignition key contacts, the stop buttons and the starter button.
3) Check the start-up solenoid.
4) If components are in good condition, check that the cable harness connecting them is not interrupted.
5) Check if there is continuity of the Purple-White cable between the start-up relay and the control unit
connector.
Horn control
KEY
1. Battery
2. Fuse No. 1
3. Ignition switch contacts
4. Fuse No. 5
5. Horn button
6. Horn
WARNING
ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS
DISCONNECTED.
1) Check fuses No. 1 and 5, the ignition key contacts and the horn button.
2) If the components are not damaged, check wiring for continuity.
3) Check that the Yellow-Pink cable between the horn and horn button is not interrupted.
4) Check that the Black cable of the horn is grounded.
KEY
1. Battery
2. Fuse No. 1
3. Ignition switch contacts
4. Fuse No. 5
5. Turn indicator control device
6. Turn indicator switch
7. Left turn indicators
8. Right turn indicators
9. Antitheft
10. Warning light bulb
WARNING
ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS
DISCONNECTED.
1) Check the working order of bulbs.
2) Check fuses No. 1 and 5 and the ignition key contacts.
3) Check if there is intermittent voltage between the Blue-Black cable of the turn indicator control device
and the ground connection.
4) If there is no voltage, check that the cable harness is not interrupted.
5) Check the turn indicator switch.
6) Check that the Blue-Black cable between the turn indicator control device and the turn indicator switch
is not interrupted.
7) Check that the Pink and White-Blue cables connecting the bulbs and the turn indicator switches are
not interrupted.
8) Check the bulbs ground connection.
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 be-
tween 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 in-
dication 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
BULBS
Specification Desc./Quantity
1 Low beam light bulb Type: Halogen H7
Quantity: 1
Power: 12V - 55W
2 High beam light bulb Type: Halogen H7
Quantity: 1
Power: 12V - 55W
3 Front tail light bulb Type: LED
Quantity: 1 Right - 1 Left
Power: -
4 Front turn indicator light bulb Type: Spherical BAU 15s
Quantity: 1 Right - 1 Left
Power: 12V - 10W
5 Stop light/rear daylight running light bulb Type: LED
Quantity: 1 Right - 1 Left
Power: -
6 Rear turn indicator light bulb Type: Spherical BAU 15s
Quantity: 1 Right - 1 Left
Power: 12V - 10W
7 License plate light bulb Type: All glass W5W
Quantity: 1
Power: 12V - 5W
Specification Desc./Quantity
8 Helmet compartment light bulb Type: Cylindrical C5W
Quantity: 1
Power: 12V - 5W
9 Instrument panel lighting bulb Type: LED
Quantity: 4
Power: -
Line for daylight running lights and instrument panel lighting line
In the event of a malfunction, check:
- Efficiency of the bulbs
- Fuses No. 1 and 5
- Ignition key contacts
- Cable harness continuity
High beam/low beam light line
In the event of a malfunction, check:
- Efficiency of the bulbs
- Light switch
- Headlight from solenoid
- Fuses No. 1, 4, 5 and 6
- Ignition key contacts
- Cable harness continuity
Fuses
FUSES
Specification Desc./Quantity
Fuse No. 1 Capacity: 30 A
Protected circuits: general, recharge battery
Live: fuses No. 5 and 6
Fuse No. 2 Capacity: 15 A
Protected circuits: battery-powered: antitheft pre-installation,
saddle release control unit pre-installation, electric fan relay
(contact)
Fuse No. 3 Capacity:10 A
Protected circuits:electronic control unit, injection load sole-
noid, (contact)
Fuse No. 4 Capacity: 15 A
Protected circuits: battery-powered headlight relay (contact),
instrument panel, battery-powered LV socket, helmet compart-
ment bulb, key powered saddle release actuator
Fuse No. 5 Capacity: 10 A
Protected circuits: key powered: antitheft pre-installation,
saddle release control unit pre-installation, turn indicator con-
trol device, high-beam flash, instrument panel, daylight running
lights, horn, stop lights, start-up enabling switch, license plate
light
Fuse No. 6 Capacity: 5A
Protected circuits: Protected circuits: headlight relay key
powered (coil), immobilizer antenna, electronic control unit, in-
jection load solenoid (coil)
Dashboard
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 re-
quired, 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 standard 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 to 14.70V
- Initial charge voltage equal to 0.3 to 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 battery rated capacity
- Charge time: Maximum 5 h
Battery installation
2) Electrolyte preparation.
Remove the container of the electrolyte from the
pack. Remove and preserve cover strips from the
container, in fact, the strip will later be used as a
closing cover.
Note: Do not pierce the sealing of the container or
the container itself because inside there is sulphu-
ric acid.
i - The battery is now completely activated, disconnect the battery charger from the fuel supply grid,
disconnect the clamps from the battery and proceed to fitting the battery on the vehicle.
Connectors
PICKUP CONNECTOR
1.Engine speed sensor ECU positive (Red)
2.Engine speed sensor ECU negative (Brown)
3. Oil pressure sensor (White)
INJECTOR CONNECTOR
1. Power from relay (Black-Green)
2. Negative from control unit (Yellow-Red)
HV COIL CONNECTOR
1. Negative from control unit (Red-Black)
2. Power from relay (Black-Green)
Strumento di diagnosi
STARTER COMMAND
Function
Commands engine starting through the injection control unit.
Operation / Operating principle
The starter button, the brake switches, the starter command relay and the injection control unit between
PIN 5 and 10 are involved.
ELECTRICAL ERRORS
Starter command P0170 - shorted to positive.
Error cause
Shorted to positive: excessive voltage at PIN 10 of the control unit connector.
Troubleshooting
Shorted to positive:
- This malfunction is detected with a brake activated and the starter button pressed (voltage of 12V read
at PIN 5)
- If the battery voltage does not drop (thanks to the absorption of the starter command relay excitation
coil) the control unit understands that PIN 10 is shorted to battery.
- Restore the cabling (if the short is in the cabling) or the relay (if the short is in the relay).
1. Injection ECU
2. Instrument panel
3. Control unit ground
4. Ground lead
Engine temperature sensor P0115 - open circuit or shorted to positive / shorted to negative.
Error cause
Open circuit or shorted to positive: interruption of the circuit or excessive voltage at PIN 13 of the control
unit connector. Shorted to negative: null voltage between PIN 13 and 15 of the control unit connector.
Troubleshooting
The circuit is open:
- Disconnect the connector of the control unit.
- Measure the resistance value of the sensor at different temperatures between PIN 13 and 15.
- Disconnect the sensor connector.
- Verify continuity of the cabling between the sensor connector and the control unit connector: Control
unit PIN 13 - sensor PIN 1 and control unit PIN 15 - sensor PIN 3. Restore the cabling if necessary.
- If the cabling is intact but the sensor resistance value is incorrect, this means that the sensor is faulty
and must be replaced, otherwise proceed with the checks.
Shorted to positive:
- With the sensor connector and the control unit disconnected, verify that the fault is shorted with the
battery positive of sensor connector PIN 1 (or control unit PIN 13) and restore the cabling.
Shorted to negative:
- Disconnect the sensor connector.
- Check the sensor connector PIN 1 ground insulation.
- If there is no ground insulation restore the cabling.
- If PIN 1 is insulated from the ground and the error persists, this means that there is a probable fault
in the control unit.
LAMBDA PROBE
Function
In charge of telling the control unit whether the
mixture is lean or rich.
Operation / Operating principle
Based on the difference of oxygen in the exhaust
fumes and the environment, this generates volt-
age which is read and interpreted by the injection
control unit.
Pin-out:
1. Signal to the control unit (+)
2. Signal to the control unit (-)
ELECTRICAL ERRORS
Check the air-fuel ratio / Lambda probe P0130 - short to positive / open circuit, short to negative or
carburetion excessively lean / signal not plausible for abnormal title correction or probe signal fault.
Error cause
Shorted to positive: excessive voltage at PIN 11 or PIN 12 of the control unit connector. Circuit open or
shorted to negative: interruption of the circuit or null voltage between control unit connector PIN 11 and
12.
Troubleshooting
Shorted to positive:
- Disconnect the control unit connector and the sensor connector.
- Verify that there is no short to battery positive on sensor connector PIN 1 (corresponding to control
unit connector PIN 11); if there is a short, restore the cabling.
- Verify that there is no short to battery positive on sensor connector PIN 2 (corresponding to control
unit connector PIN 12); if there is a short, restore the cabling.
The circuit is open:
- Disconnect the control unit connector and the sensor connector.
- Verify continuity of the cabling between the sensor connector and the control unit connector: Control
unit PIN 11 - sensor PIN 1 and control unit PIN 12 - sensor PIN 2. Restore the cabling if necessary.
- If the cabling is intact and the error persists, proceed with the following checks.
Shorted to negative:
- Disconnect the sensor connector and the control unit connector.
- Check the sensor connector PIN 1 ground insulation. In the absence of insulation restore the cabling.
- Check the sensor connector PIN 2 from ground insulation. In the absence of insulation restore the
cabling.
- If PIN 1 and PIN 2 are insulated from the ground and the error persists, this means that there is a
probable fault in the control unit.
INJECTOR
Function
To supply the correct amount of petrol at the right
timing.
Operation / Operating principle
Injector coil is excited for the petrol passage to
open.
Pin-out:
1. Relay powered
2. Control unit ground
ELECTRICAL ERRORS
Injector P0201 - shorted to positive / shorted to negative / open circuit.
Error cause
Shorted to positive: excessive voltage at PIN 34 of the control unit connector.
Shorted to negative: null voltage at PIN 1 of the injector connector.
The circuit is open: interruption of the circuit.
Troubleshooting
Shorted to positive:
- Disconnect the injector connector, turn the key to ON and activate the component through the diag-
nostics instrument.
- Verify the absence of voltage at the injector connector PIN 2; if present, restore the cabling, otherwise
proceed with the following checks.
Shorted to negative:
- Disconnect the injector connector, turn the key to ON and activate the component through the diag-
nostics instrument.
- Verify the presence of voltage at the ends of the injector connector; if there is no voltage, restore the
cabling, otherwise proceed with the following checks.
The circuit is open:
- Carry out the check procedure of the injector and control unit connectors.
- Verify continuity of the cabling between the control unit connector and the injector connector (control
unit PIN 34 - injector PIN 2). In the absence of continuity restore the cabling.
FUEL PUMP
ELECTRICAL ERRORS
Fuel pump relay P0230 - shorted to positive / shorted to negative / open circuit.
Error cause
Shorted to positive: excessive voltage at PIN 22 of the control unit connector.
Shorted to negative: null voltage at PIN 85 of the injection relay.
The circuit is open: interruption of the circuit.
Troubleshooting
Shorted to positive:
- Disconnect the injection relay (No. 58 on the electrical circuit diagram), turn the key to the ON position
and activate the relay through the diagnostics instrument.
- Verify the presence of voltage between relay connector PIN 86 and 85 toward the cabling.
- If no voltage is read, disconnect the control unit and verify insulation from battery positive of the relay
PIN 86 (or control unit PIN 22). Restore the cabling if necessary.
Shorted to negative:
- Disconnect the injection relay (No. 58 on the electrical circuit diagram) and the control unit.
- Verify ground insulation of the relay connector PIN 86 and 85 toward the cabling: if there is no insu-
lation, restore the cabling.
The circuit is open:
- Disconnect the injection relay (No. 58 on the electrical circuit diagram) and the control unit.
- Verify continuity of the cabling between the relay and control unit: Relay PIN 86 - control unit PIN 22.
Restore the cabling if necessary.
COIL
Function
Allows generation of the electrical discharge on
the spark plug, with an increase of voltage.
Pin-out:
1. Activation by control unit (control unit side PIN
1)
2. Relay powered (PIN 87 relay side)
ELECTRICAL ERRORS
H.V. Coil P0351 - shorted to positive / open circuit or shorted to negative.
Error cause
Shorted to positive: excessive voltage at PIN 1 of the control unit connector.
Circuit open or shorted to negative: interruption of the circuit or null voltage at PIN 1 of the control unit
connector.
Troubleshooting
Shorted to positive:
- Disconnect the coil connector, turn the key to ON and activate the component through the diagnostics
instrument.
- Verify the presence of voltage on the coil connector PIN 1: if present, restore the cabling, otherwise
replace the coil.
The circuit is open:
- Carry out the check procedure of the coil and control unit connectors.
- Verify continuity of the cabling between the coil and control unit: Coil PIN 1 - control unit PIN 1. In the
absence of continuity restore the cabling.
- Verify, with the key turned ON, the presence of voltage on the coil connector PIN 2: If no voltage is
read, verify the continuity of the cabling between coil and injection relay (No. 35 on the electrical circuit
diagram): Coil PIN 2 - relay PIN 87.
- If the above tests provided a positive result, the coil should be replaced.
Shorted to negative:
- Disconnect the control unit connector and the coil connector.
- Verify the coil connector PIN 1 ground insulation (or control unit connector PIN 1). Restore the cabling
if necessary.
ELECTRICAL ERRORS
Fan relay P0480 - shorted to positive / shorted to negative / open circuit.
Error cause
Shorted to positive: excessive voltage at PIN 24 of the control unit connector.
Shorted to negative: null voltage at PIN 24 of the control unit connector.
The circuit is open: interruption of the circuit.
Troubleshooting
Shorted to positive:
- Disconnect the fan control relay (No. 45 on the electrical circuit diagram) and, turning the key to the
ON position, measure the voltage read at the relay connector PIN 85 toward the cabling: if the voltage
is 12V restore the cabling. If the voltage is zero replace the relay.
Shorted to negative:
- Disconnect the fan control relay (No. 45 on the electrical circuit diagram) and the control unit.
- Verify ground insulation of the cable between the fan control relay (PIN 85) and the control unit (PIN
24). Restore the cabling if necessary.
The circuit is open:
- Carry out the check procedure of the control unit and relay connectors.
- Verify electrical continuity of the cable between the relay connector (PIN 85) and the control unit
connector (PIN 24).
- Verify electrical continuity of the cable between the relay connector (PIN 30) and the secondary fuse
holders.
- Verify continuity between relay PIN 85 and PIN 86. If there is no continuity replace the relay.
This section describes the operations to carry out when removing the engine from the vehicle.
SILENCER REMOVAL
- Undo the front screw.
ENG VE - 125
Engine from vehicle BV 350
FITTING
To fit, follow the removal steps but in reverse order; be careful to tighten to the specified torques.
N.B.
ALWAYS REPLACE THE GRAPHITE BUSHING BETWEEN THE MANIFOLD AND THE SILENCER.
SILENCER
Name Torque in Nm
Silencer heat guard fixing screw (2.95÷3.68)lb ft (4÷5)Nm
Screw for fixing silencer to supporting arm (14.75÷18.43)lb ft (20÷25)Nm
Lambda probe tightening on exhaust manifold (29.50÷36.87)lb ft (40÷50)Nm
Exhaust manifold-silencer clamp tightening (8.85÷9.58)lb ft (12÷13)Nm
Nuts fixing the exhaust manifold to the head (11.80÷13.27)lb ft (16÷18)Nm
Joint pipe (Setting load 440.92-1322.77 lb - LOCTITE 603) (Setting load
200-600 Kg - LOCTITE 603)
ENG VE - 126
BV 350 Engine from vehicle
ENG VE - 127
Engine from vehicle BV 350
ENG VE - 128
BV 350 Engine from vehicle
ENG VE - 129
Engine from vehicle BV 350
ENG VE - 130
BV 350 Engine from vehicle
- Operating with care and with the necessary precautions, remove the engine from the vehicle.
- If necessary, remove the swinging arm as described in the section "Suspensions/Swinging arm".
When refitting the engine onto the vehicle, carry out the removal operations but in reverse order and
respect the tightening torques shown in the Specifications Chapter.
ENG VE - 131
Engine from vehicle BV 350
- Check the engine oil level and if necessary, top it up with the recommended type.
- Fill and bleed the cooling circuit.
- Check accelerator and electric devices for correct functioning.
CAUTION
PAY PARTICULAR ATTENTION TO POSITIONING THE THROTTLE CONTROL TRANSMISSION
PROPERLY.
ENG VE - 132
INDEX OF TOPICS
ENGINE ENG
Engine BV 350
This section describes the operations to be carried out on the engine and the tools to be used.
Automatic transmission
Transmission cover
Specific tooling
020917Y Driven pulley lock
ENG - 134
BV 350 Engine
See also
Air duct
Air duct
ENG - 135
Engine BV 350
Specific tooling
020376Y Adaptor handle
020357Y 32x35-mm Adaptor
020439Y 17-mm guide
001467Y002 Driver for OD 73 mm bearing
- Use the heat gun to heat the inner part of the lid.
CAUTION
DO NOT HEAT EXCESSIVELY SO AS NOT TO DAMAGE
THE PAINTWORK.
Specific tooling
020151Y Air heater
Specific tooling
020376Y Adaptor handle
020358Y 37x40-mm Adaptor
020439Y 17-mm guide
ENG - 136
BV 350 Engine
Specific tooling
020917Y Driven pulley lock
ENG - 137
Engine BV 350
- To fit, follow the removal steps but in reverse order, being careful to tighten to the specified torque.
CAUTION
ALWAYS USE A NEW NUT FOR RETAINING THE CLUTCH OUTPUT SHAFT, THEN PROCEED TO
THE CAULKING.
Locking torques (N*m)
Clutch output shaft nut (88.51 ÷ 95.88) lb ft (120 ÷ 130) Nm
ENG - 138
BV 350 Engine
See also
Removing the hub cover
COVER REVISION
- Adequately support the cover and using a screw-
driver remove the seal ring.
Specific tooling
001467Y007 Driver for OD 54-mm bearings
ENG - 139
Engine BV 350
Specific tooling
001467Y007 Driver for OD 54-mm bearings
020376Y Adaptor handle
020358Y 37x40-mm Adaptor
Specific tooling
020151Y Air heater
020376Y Adaptor handle
020360Y 52x55-mm Adaptor
020364Y 25-mm guide
- Insert a new seal ring and grease the seal lips.
Specific tooling
020376Y Adaptor handle
020360Y 52x55-mm Adaptor
ENG - 140
BV 350 Engine
DISASSEMBLY
- Insert the clutch assembly in the special tool and
tighten the three wing nuts until you hear the end
of stroke.
- Prepare two aluminium protections in the vice
and tighten the shaft of the driven pulley.
Specific tooling
020919Y Clutch discs disassembly tool
ENG - 141
Engine BV 350
ENG - 142
BV 350 Engine
ENG - 143
Engine BV 350
ENG - 144
BV 350 Engine
CAUTION
ENG - 145
Engine BV 350
ENG - 146
BV 350 Engine
Characteristic
Clutch springs
Free spring measurement 0.0623 in (15.3 mm)
Clutch spring wear limit
0.59 in (15.0 mm)
Characteristic
Clearance recovery spring «A» standard di-
mensions
(0.1260±0.0039)in; (3.2±0.1)mm)
Clearance recovery spring wear limit
0.1102 in (2.8 mm)
Characteristic
Clutch discs thickness
Conductor disc thickness «B» = (0.11811±0.00315)in ((3.00±0.08)mm)
Trimmed disc duct thickness «C» = (0.07677±0.001968)in ((1.95±0.05)mm)
Trimmed disc duct thickness «D» = (0.05512±0.001378)in ((1.400±0.035) mm)
CLUTCH DISCS REVISION
Check the clutch discs for damage or signs of
wear: In this case, replace them all.
Measure the thickness of the discs in four posi-
tions, and if they do not meet specifications, re-
place them all.
Characteristic
Clutch discs thickness
Conductor disc thickness «B» = (0.11811
±0.00315)in ((3.00±0.08)mm)
Trimmed disc duct thickness «C» = (0.07677±0.001968)in
((1.95±0.05)mm)
Trimmed disc duct thickness «D» = (0.05512±0.001378)in
((1.400±0.035) mm)
ENG - 147
Engine BV 350
Characteristic
Clutch discs wear limit
Conductor disc wear limits «B» = 0.10236 in (2.6 mm)
Trimmed duct disc wear limits «C» = 0.06693 in (1.7 mm)
CLUTCH DISCS REVISION: MAXIMUM DEFOR-
MATION
Measure the maximum deformation of the discs by
positioning them on a reference plane and check-
ing with a feeler gauge. If out of specification,
replace them all.
Characteristic
Clutch discs maximum deformation
Max. duct disc unevenness «D»= 0.00787 in (0.2
mm)
ENG - 148
BV 350 Engine
REASSEMBLY
- Working in reverse order to the removal, insert
the components while taking care to follow the fol-
lowing guidelines:
- Place the rollers as shown in the photo, after ev-
ery two leave a clearance so that each pair has its
opposite for proper balance.
Recommended products
AGIP GEAR SAE 80W-90 Lubricant for gear-
boxes and transmissions.
API GL-4
CAUTION
ENG - 149
Engine BV 350
ENG - 150
BV 350 Engine
Specific tooling
020919Y Clutch discs disassembly tool
FINAL CHECK
Once the clutch is assembled, turn by hand the exit axis to the final reduction.
The rotation must be free.
If you feel resistance in the movement, or if you detect impediments, disassemble the clutch again and
check the correct installation.
ENG - 151
Engine BV 350
Specific tooling
001467Y006 Pliers to extract 20 mm bearings
001467Y007 Driver for OD 54-mm bearings
Specific tooling
020084Y 20-mm diameter punch
ENG - 152
BV 350 Engine
Specific tooling
020444Y Tool for fitting/ removing the driven
pulley clutch
020444Y009 wrench 46 x 55
- Turn the key to unscrew the nut.
- Adjust the specific tool command screw to re-
lease the torque server spring.
ENG - 153
Engine BV 350
• upper cap;
• spring;
• lower spring support;
• synthetic ring.
ENG - 154
BV 350 Engine
Recommended products
MONTBLANC MOLYBDENUM GREASE -
Grease with molybdenum disulphide
N.B.
GREASE USING THE CHANNELS IN THE PULLEY.
ENG - 155
Engine BV 350
ENG - 156
BV 350 Engine
Specific tooling
020444Y Tool for fitting/ removing the driven
pulley clutch
Specific tooling
020444Y009 wrench 46 x 55
Characteristic
Unloaded spring length
3.9960 in (101.5 mm)
Acceptable limit after use
3.8582 in (98 mm)
ENG - 157
Engine BV 350
- Working as described in section «Fitting the hub cover» proceed to the locking of the clutch assem-
bly.
Drive-belt
- Make sure the drive belt is not damaged and does not show abnormal wear.
ENG - 158
BV 350 Engine
Specific tooling
020442Y Pulley lock wrench
ENG - 159
Engine BV 350
Characteristic
movable driving half-pulley bushing: Standard
Diameter
1.1811(+0 +0.000826) in (30(+0 +0.021)mm)
movable driving half-pulley bushing: Maxi-
mum allowable diameter
Ø1.0283in (26.12mm)
Sliding bushing: Standard Diameter
Ø1.18110(-0.00079 +0.00161)in (Ø30 (-0.02
+0.041)mm)
Sliding bushing: Minimum admissible diame-
ter
Ø1.021in (25.95 mm)
Roller: Standard diameter
(Ø0.9842±0.0039)in ((Ø25 mm ±0.1)mm)
ENG - 160
BV 350 Engine
Specific tooling
020442Y Pulley lock wrench
CAUTION
DURING THE INSTALLATION PAY SPECIAL ATTENTION
TO THE ASSEMBLY OF THE BELLEVILLE SPRING, AS
SHOWN IN FIGURE.
ENG - 161
Engine BV 350
End gear
ENG - 162
BV 350 Engine
Specific tooling
020918Y Clutch retainer
ENG - 163
Engine BV 350
ENG - 164
BV 350 Engine
REMOVAL
Removing the clutch shaft bearing
- Remove the screw and countersunk washer.
- Using the specific tools remove the bearing.
Specific tooling
020376Y Adaptor handle
020357Y 32x35-mm Adaptor
020363Y 20-mm guide
Specific tooling
020376Y Adaptor handle
020357Y 32x35-mm Adaptor
020363Y 20-mm guide
Specific tooling
020376Y Adaptor handle
020456Y Ø 24-mm adaptor
020412Y 15-mm guide
FITTING
- Heat the crankcase by means of the specific tool and then insert the bearings.
Specific tooling
ENG - 165
Engine BV 350
Specific tooling
020376Y Adaptor handle
020359Y 42x47-mm Adaptor
020363Y 20-mm guide
Specific tooling
020376Y Adaptor handle
020360Y 52x55-mm Adaptor
020363Y 20-mm guide
Specific tooling
020376Y Adaptor handle
020359Y 42x47-mm Adaptor
020412Y 15-mm guide
Recommended products
Loctite 242 product description
Apply LOCTITE medium type 242 threadlock
ENG - 166
BV 350 Engine
Characteristic
Driven pulley shaft standard sizes
A: 0.9842(-0.00039 -0.00079)in (25(-0.01 -0.02)
mm)
B: 0.7716(-0.0079 -0.0123)in (19.6(-0.20 -0.33)mm)
Clutch output shaft standard sizes
C: 0.7874(-0 -0.005)in (20 (-0 -0.013)mm)
D: 0.7574(-0.0004 -0.0008)in (20(-0.01 -0.02)mm)
Wheel axle
E: 1.3779(-0 -0.013)in (35(-0 -0.013)mm)
F: 1.1811(-0.0051 -0.0102)in (30(-0.13 -0.26)mm)
Intermediate gear
G: 0.7874(-0.0004 -0.0008)in (20(-0.01 -0.02)mm)
H: 0.7874(-0.0004 -0.0008)in (20(-0.01 -0.02)mm)
ENG - 167
Engine BV 350
REMOVAL
Removing the Wheel axle bearing
- Remove the Seeger ring.
Specific tooling
020489Y Hub cover support stud bolt kit
020376Y Adaptor handle
020357Y 32x35-mm Adaptor
020483Y 30-mm guide
- Remove the hub cover from the stud bolts and
using the specific tools pull out the oil seal.
Specific tooling
020376Y Adaptor handle
020359Y 42x47-mm Adaptor
ENG - 168
BV 350 Engine
Specific tooling
001467Y003 Nut
001467Y004 Lug / Taper pin
001467Y005 Screw
001467Y006 Pliers to extract 20 mm bearings
001467Y035 Bearing housing, out ø 47 mm
FITTING
Fitting the Intermediate gear bearing
- Heat the crankcase by means of the specific tool
and then insert the bearings.
Specific tooling
020151Y Air heater
Specific tooling
020376Y Adaptor handle
020359Y 42x47-mm Adaptor
020363Y 20-mm guide
Specific tooling
020376Y Adaptor handle
020360Y 52x55-mm Adaptor
020483Y 30-mm guide
ENG - 169
Engine BV 350
- Insert a new seal ring with the seal facing the in-
side of the hub by means of the appropriate tool.
- Grease the sealing lips.
Specific tooling
020376Y Adaptor handle
020360Y 52x55-mm Adaptor
ENG - 170
BV 350 Engine
Specific tooling
020918Y Clutch retainer
Recommended products
THREE BOND TB1207B Liquid sealant
Liquid gasket Three Bond TB1207B
CAUTION
ENG - 171
Engine BV 350
THE FOLLOWING OIL REDUCTION FILLING PROCEDURE MUST BE CARRIED OUT ONLY WITH
THE MOTOR FITTED ON THE VEHICLE, ON THE CENTRE STAND IN FLAT LAND.
- Restore the level of oil inside duction unit with the
recommended product, acting on the filler screw
until touching.
- Tighten to the specified torque.
Recommended products
AGIP GEAR SAE 80W-90 Lubricant for gear-
boxes and transmissions.
API GL-4
Characteristic
Final reduction unit oil
approx 0.122cuin (500cc)
Flywheel cover
ENG - 172
BV 350 Engine
ENG - 173
Engine BV 350
- Remove the flywheel and the pick-up complete with cable harness.
ENG - 174
BV 350 Engine
Characteristic
Pick-up rotor measurement
(0.0157÷0.0295)in (0.4÷0.75)mm
- Perform the procedure in reverse order of disassembly, taking care to tighten to specified torque.
ENG - 175
Engine BV 350
Specific tooling
020916Y Support plate
ENG - 176
BV 350 Engine
Specific tooling
020627Y Flywheel lock wrench
Specific tooling
020467Y Flywheel extractor
- Remove the tool and unscrew the nut.
- Remove the complete flywheel paying attention
to recover the tongue.
See also
ENG - 177
Engine BV 350
Intermediate gear
- Visually inspect the surfaces, if there is no abnormal wear, grease the housing thoroughly and insert
the intermediate gear.
Recommended products
Loctite 243 Medium-strength threadlock
Medium Loctite 243 threadlock
ENG - 178
BV 350 Engine
- Perform the procedure in reverse order of disassembly, taking care to tighten to specified torque.
ENG - 179
Engine BV 350
ENG - 180
BV 350 Engine
ENG - 181
Engine BV 350
ENG - 182
BV 350 Engine
ENG - 183
Engine BV 350
ENG - 184
BV 350 Engine
ENG - 185
Engine BV 350
ENG - 186
BV 350 Engine
ENG - 187
Engine BV 350
Specific tooling
020382Y Tool to extract valve cotters
020382Y012 bush (valve removing tool)
ENG - 188
BV 350 Engine
Specific tooling
020431Y Valve oil seal extractor
ENG - 189
Engine BV 350
ENG - 190
BV 350 Engine
ENG - 191
Engine BV 350
- Provisionally fit the piston into the cylinder, without any base gasket.
- Assemble a dial gauge on the specific tool.
Specific tooling
020921Y Piston position checking tool
- By means of the table, see the Specifications chapter identify the cylinder base gasket thickness to
be used for refitting. Correctly identify the cylinder base gasket thickness to keep the correct compres-
sion ratio.
- Remove the special tool and the cylinder.
See also
Slot packing system
ENG - 192
BV 350 Engine
ENG - 193
Engine BV 350
Specific tooling
020927Y Piston assembly band
Recommended products
eni i-Ride scooter 15W-50 Synthetic-based lu-
bricant for four stroke engines.
JASO MA, MA2 - API SJ - ACEA A3
ENG - 194
BV 350 Engine
Recommended products
eni i-Ride scooter 15W-50 Synthetic-based lu-
bricant for four stroke engines.
JASO MA, MA2 - API SJ - ACEA A3
N.B.
BEFORE FITTING THE CYLINDER, CAREFULLY BLOW OUT THE LUBRICATION DUCT AND OIL
THE CYLINDER LINER.
ENG - 195
Engine BV 350
ENG - 196
BV 350 Engine
Cylinder Head
ENG - 197
Engine BV 350
Characteristic
Valve clearance
Intake: 0.00393in (0.10 mm)
Exhaust: 0.00590in (0.15 mm)
ENG - 198
BV 350 Engine
Characteristic
Valve clearance
Intake: 0.00393in (0.10 mm)
Exhaust: 0.00590in (0.15 mm)
ENG - 199
Engine BV 350
N.B.
TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP-
TER.
See also
Cylinder Head
Specific tooling
020306Y Punch for assembling valve seal
rings
020382Y Valve cotters equipped with part 012
removal tool
020382Y012 bush (valve removing tool)
ENG - 200
BV 350 Engine
Cylinder Head
ENG - 201
Engine BV 350
ENG - 202
BV 350 Engine
ENG - 203
Engine BV 350
Crankcase - crankshaft
ENG - 204
BV 350 Engine
ENG - 205
Engine BV 350
ENG - 206
BV 350 Engine
ENG - 207
Engine BV 350
Characteristic
«A»
AXIS CYLINDER
- The oil feeding channel section is also affected by the bushings driving depth compared with the
crankshaft axial clearance of the limiting surface.
N.B.
TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP-
TER.
See also
Crankcase - crankshaft - connecting rod
Coupling chart
N.B.
TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP-
TER.
See also
Crankcase - crankshaft - connecting rod
ENG - 208
BV 350 Engine
CAUTION
ENG - 209
Engine BV 350
Specific tooling
020163Y Crankcase splitting plate
020335Y Magnetic support for dial gauge
Characteristic
Crankshaft-crankcase axial clearance (H)
(0.005÷0.016)in (0.15 ÷ 0.43)mm
Studs
Characteristic
Driving depth of stud bolts «A»
(5.4921÷0.0197)in (139.5+0.5)mm
Lubrication
ENG - 210
BV 350 Engine
Conceptual diagrams
The lobe pump «F» sucks the oil from the sump, through the mesh pre-filter «C», it pushes it into the
cartridge filter «E» where there is also a safety valve «D».
Through the suitable passages found in the crankcases, the oil enters the crank chamber «G» where
the main bearings are lubricated and the big end (with high pressure), the piston pin and connecting
rod small end via spray «H».
Afterwards, the oil, through a nozzle «M» whose function is to reduce the flow rate, reaches the timing
system where it lubricates the camshaft «A» and from there, the valves and rockers. The oil passes
through the timing chain duct and returns to the sump «B» by gravity.
In the system there is a minimal oil pressure sensor «I» and a spray that serves to lubricate the stator
«L».
ENG - 211
Engine BV 350
Characteristic
Oil pressure
Operating pressure
- At 1,650 rpm(g/min): (7.25÷17.40)PSI (50÷10)kPa (0.5÷1.2)
bar
- A 6,000 rpm(g/min): (46.41÷60.92)PSI (320÷420)kPa
(3.2÷4.2)bar
Removal
ENG - 212
BV 350 Engine
ENG - 213
Engine BV 350
Refitting
Oil pump
Removal
ENG - 214
BV 350 Engine
Inspection
ENG - 215
Engine BV 350
Characteristic
Axial rotor clearance
Limit values admitted: 0.00354in (0.09mm)
Distance between the outer rotor and the pump
body
Admissible limit clearance: 0.00787in (0.20mm)
Distance between the rotors
Admissible limit clearance: 0.00472in (0.12mm)
ENG - 216
BV 350 Engine
Refitting
Recommended products
Loctite 243 Medium-strength threadlock
Medium Loctite 243 threadlock
Characteristic
Standard length
2.063in (52.4mm)
ENG - 217
Engine BV 350
Water pump
Removal
ENG - 218
BV 350 Engine
Specific tooling
001467Y002 Driver for OD 73 mm bearing
ENG - 219
Engine BV 350
Fitting
Specific tooling
020376Y Adaptor handle
020375Y 28 x 30 mm adaptor
ENG - 220
BV 350 Engine
Specific tooling
ENG - 221
Engine BV 350
ENG - 222
BV 350 Engine
ENG - 223
INDEX OF TOPICS
INJECTION INJEC
BV 350 Injection
COMPONENT LAYOUT
Specification Desc./Quantity
1 Battery 12V - 10Ah
2 Diagnostics socket connector
3 Electric fan solenoid
4 Injection load solenoid
5 Water temperature sensor
6 Throttle body and electronic injection control unit (MIU)
7 Fuel injector
8 HV coil
9 Lambda probe
10 Fuel pump
11 Engine Speed sensor
INJEC - 225
Injection BV 350
In all conditions of use, mixture preparation is managed by modifying the injector opening time.
The fuel system pressure is kept constant based on the ambient pressure.
INJEC - 226
BV 350 Injection
In any case, when the fault is no longer present, the data storage is automatically cleared after 16 cycles
of use (cold start, running at regular engine temperature, stop).
The diagnostic tester is also required to adjust the idle mixture.
Specific tooling
020680Y Diagnosis Tool
The MIU control unit power supply is furthermore controlled by the emergency switch; that is to provide
further safety for the vehicle.
Precautions
Troubleshooting hints
1 A MIU failure is more likely to be due to the connections than to the components.
Before troubleshooting the MIU system, carry out the following checks:
A: Electrical power supply
a. Battery voltage
b. Blown fuse
c. Solenoids
d. Connectors
B: Chassis ground
C: Fuel system
a. Faulty fuel pump
b. Dirty fuel filter
D: Ignition system
a. Faulty spark plug
b. Faulty coil
c. Faulty shielded cap
E: Intake circuit
a. Air filter dirty
b. b. Dirty by-pass circuit
c. c. Faulty stepper motor
INJEC - 227
Injection BV 350
F: Other
a. Incorrect distribution timing
b. Wrong idle mixture
c. Incorrect reset of the throttle valve position sensor
2 MIU system faults may be caused by loose connectors. Make sure that all connections have been
correctly made.
Check the connectors taking into consideration the following point:
A check that the terminals are not bent.
B check that the connectors have been properly connected.
C check whether the malfunction can be fixed by shaking the connector slightly.
3 Check the entire system before replacing the MIUIf the fault is fixed by replacing the MIU control unit,
install the original control unit again and check if the fault occurs again.
4 Use a multimeter with an internal resistance of more than 10K Ohm /V when troubleshooting. Instru-
ments that are not suitable might damage the MIU central control unit. Use instruments with definitions
over 0.1V and 0.5 W , the precision must be greater than 2%.
1. Before repairing any part of the injection system, check if any faults have been stored. Do not dis-
connect the battery before checking for faults.
2. The fuel supply system is pressurised at 36.26PSI (250KPa) (2.5bar). Before disconnecting the fast-
release fitting of the fuel supply pipe, check that there are no naked flames. Do not smoke. Act with
caution to avoid spraying fuel to your eyes.
3. When repairing electric components, the battery must always be disconnected unless it is strictly
necessary for the battery to be connected.
4. When functional checks are performed, make sure that the battery voltage exceeds 12V.
5. Before attempting to start the vehicle, ensure that there are at least two litres of fuel in the tank.
Failure to respect this norm will damage the fuel pump.
6. If a long period is envisaged with the vehicle not in use, fill the tank to at least the halfway mark. This
will ensure the pump will be covered by fuel.
7. When washing the vehicle, do not spray excessive water on electric components and wiring.
8. In the event of ignition problems, begin troubleshooting from the battery and the injection system
connections.
9. Before disconnecting the MIU control unit connector, perform the following steps in the order shown:
- Set the switch to «OFF»
- Disconnect the battery
Failure to respect this norm may damage the control unit.
10. Do not invert the poles when fitting the battery.
11. In order to not cause damage, disconnect and reconnect the connectors of the MIU system only
after proven necessary. Before reconnecting, check that the connectors are dry.
INJEC - 228
BV 350 Injection
12. When carrying out electric inspections, do not force the tester probes into the connectors. Do not
take measurements not specifically foreseen by the manual.
13. At the end of every check performed with the diagnostic tester, remember to protect the system
connector with its cap. Failure to observe this precaution may damage the MIU control unit.
14. Before reconnecting the quick couplers of the power supply system, check that the terminals are
perfectly clean.
Terminals setup
TERMINAL LAYOUT
Specification Desc./Quantity
1 HV coil (Red-Black)
2 -
3 Tip over switch (Grey - Black)
4 Engine switch (Orange)
5 Starter switch (Purple)
6 +Live supply (Orange - Blue)
7 Ground lead 1 (Black)
8 -
9 + Battery (Red - White)
10 Starter enable (Purple-White)
11 + Lambda probe (Green - Blue)
12 - Lambda probe (Light blue - Black)
13 Water temperature sensor (Light blue - Green)
14 Antenna (Orange - White)
15 Sensor ground (Grey - Green)
16 "K" line diagnostics (Orange - Black)
17 Immobilizer LED (Yellow)
18 -
19 Side stand (Brown - Red)
20 Engine speed sensor - (Brown)
21 -
22 Injection load solenoid (Black- Purple)
23 Ground lead 2 (Black)
24 Electric fan relay (Green- White)
25 Led injection telltale light (Brown - White)
26 -
27 -
28 -
29 Engine speed sensor + (Red)
30 -
31 -
32 -
33 Light relay (White - Black)
34 Injector (Red - Yellow)
INJEC - 229
Injection BV 350
INJEC - 230
BV 350 Injection
Troubleshooting procedure
Starting difficulties
INJEC - 231
Injection BV 350
INJEC - 232
BV 350 Injection
INJEC - 233
Injection BV 350
Engine knocking
The fuel supply circuit includes the electric pump, the filter, the pressure regulator, the electro-injector
and the fuel delivery pipes.
The electrical pump is located in the tank from which the fuel is pumped and sent to the injector through
the filter.
The pressure is controlled by the pressure regulator situated in the pump assembly in the tank.
INJEC - 234
BV 350 Injection
INJEC - 235
Injection BV 350
INJEC - 236
BV 350 Injection
INJEC - 237
Injection BV 350
INJECTION LOADS
Specification Desc./Quantity
1 Battery 12V - 12 Ah
2 Fuse No. 3 10 A
3 Fuse No. 1 30 A
4 Ignition switch contacts
5 Fuse No. 6 5A
6 Injection load solenoid
7 Fuel pump
8 HV coil
9 Fuel injector
10 Injection ECU
11 Electric fan solenoid
When switched to «ON», the fuel pump starts to rotate for 2 seconds and then stops. When the engine
starts, in the presence of rpm timing signal the pump is continuously supplied.
ELECTRICAL DATA
INJEC - 238
BV 350 Injection
WARNING
TO INDICATE THE SOLENOID OF THE DESIRED FUNC-
TION, REFER TO THE PIN-CABLE COLOUR RELATION-
SHIP WITH THE ATTACHED ELECTRIC SYSTEM DIA-
GRAM.
INJEC - 239
Injection BV 350
Check the power supply line of the injection load solenoid energising coil: switching to «ON» check the
presence of battery tension, for 2 seconds, between the Orange-Blue cable and the Black-Purple cable
of the relay base. Otherwise check the continuity of the Orange-Blue cable between the fuse-box and
the relay base and of the Black-Purple cable between pin 22 of the control unit and the relay base.
N.B.
CONTINUITY TESTS MUST BE CARRIED OUT WITH THE COMPONENTS DISCONNECTED.
(SOLENOIDS, CONTROL UNIT, FUSES ETC.).
INJEC - 240
BV 350 Injection
Specific tooling
020331Y Digital multimeter
Install the specific tool for checking the fuel pressure, with the pipe fitted with the gauge.
With the battery voltage > 12 V, check the pump flow rate by disconnecting from the injector the pipe
equipped with the pressure gauge of the appropriate tool. Prepare a graduated burette with a capacity
of approx. 0.264 USgal) (0.220 UKgal) (1l). Turn the pump with active diagnosis of the PDA. Using a
pair of long flat needle-nose pliers, choke the fuel pipe making the pressure stabilise at approx.
36.259PSI (250kPa) (2.5bar). Check that within 15 seconds the pump has a flow rate of approx. 6.71cuin
(110 cc).
Specific tooling
020480Y Petrol pressure check kit
INJEC - 241
Injection BV 350
INJEC - 242
BV 350 Injection
INJECTION LOADS
Specification Desc./Quantity
1 Battery 12V - 12 Ah
2 Fuse No. 3 10 A
3 Fuse No. 1 30 A
INJEC - 243
Injection BV 350
Specification Desc./Quantity
4 Ignition switch contacts
5 Fuse No. 6 5A
6 Injection load solenoid
7 Fuel pump
8 HV coil
9 Fuel injector
10 Injection ECU
11 Electric fan solenoid
INJEC - 244
BV 350 Injection
WARNING
TO INDICATE THE SOLENOID OF THE DESIRED FUNC-
TION, REFER TO THE PIN-CABLE COLOUR RELATION-
SHIP WITH THE ATTACHED ELECTRIC SYSTEM DIA-
GRAM.
Check the power supply line of the injection load solenoid energising coil: switching to «ON» check the
presence of battery tension, for 2 seconds, between the Orange-Blue cable and the Black-Purple cable
of the relay base. Otherwise check the continuity of the Orange-Blue cable between the fuse-box and
the relay base and of the Black-Purple cable between pin 22 of the control unit and the relay base.
N.B.
CONTINUITY TESTS MUST BE CARRIED OUT WITH THE COMPONENTS DISCONNECTED.
(SOLENOIDS, CONTROL UNIT, FUSES ETC.).
INJEC - 245
Injection BV 350
With injector disconnected and the injector load solenoid disconnected, check the continuity of the
Black-Green cable between the injector connector and solenoid base.
INJEC - 246
BV 350 Injection
Specific tooling
020480Y Petrol pressure check kit
Components location
COMPONENT LAYOUT
Specification Desc./Quantity
1 Battery 12V - 10Ah
2 Diagnostics socket connector
3 Electric fan solenoid
4 Injection load solenoid
5 Water temperature sensor
6 Throttle body and electronic injection control unit (MIU)
7 Fuel injector
8 HV coil
9 Lambda probe
10 Fuel pump
INJEC - 247
Injection BV 350
Specification Desc./Quantity
11 Engine Speed sensor
Tachometer
Disconnect the fuel pipe connector. Start up the engine and wait for it to stop. With the wiring connected
to the control unit and system try to start up the engine and check that the voltage between pins 29 and
20 is around 2.8 V
INJEC - 248
BV 350 Injection
Check that the pins 20 and 29 of the control unit are isolated from each other and insulated from the
ground.
Specific tooling
020331Y Digital multimeter
HT coil
INJEC - 249
Injection BV 350
INJECTION LOADS
Specification Desc./Quantity
1 Battery 12V - 12 Ah
2 Fuse No. 3 10 A
3 Fuse No. 1 30 A
4 Ignition switch contacts
5 Fuse No. 6 5A
6 Injection load solenoid
7 Fuel pump
8 HV coil
9 Fuel injector
10 Injection ECU
11 Electric fan solenoid
The ignition system is integrated with the injection and it is a high-efficiency inductive type ignition.
The control unit manages two important parameters:
- Ignition advance
This is optimised according to the engine rpm, to the engine load, temperature and ambient pressure
With the engine at idle, the ignition advance is optimised to stabilise the speed at 1,450 ±50 rpm.
- Magnetisation time
The coil magnetisation time is controlled by the control unit. The ignition power is increased during the
engine start-up phase.
The injection system recognises the 4-stroke cycle and therefore, ignition is only controlled during
compression.
Specific tooling
020331Y Digital multimeter
INJEC - 250
BV 350 Injection
WARNING
TO INDICATE THE SOLENOID OF THE DESIRED FUNC-
TION, REFER TO THE PIN-CABLE COLOUR RELATION-
SHIP WITH THE ATTACHED ELECTRIC SYSTEM DIA-
GRAM.
Check the power supply line of the injection load solenoid energising coil: switching to «ON» check the
presence of battery tension, for 2 seconds, between the Orange-Blue cable and the Black-Purple cable
of the relay base. Otherwise check the continuity of the Orange-Blue cable between the fuse-box and
the relay base and of the Black-Purple cable between pin 22 of the control unit and the relay base.
N.B.
CONTINUITY TESTS MUST BE CARRIED OUT WITH THE COMPONENTS DISCONNECTED.
(SOLENOIDS, CONTROL UNIT, FUSES ETC.).
INJEC - 251
Injection BV 350
TEMPERATURE SENSOR
Specification Desc./Quantity
1 Instrument panel
2 Injection ECU
3 Water temperature sensor
With the connector on the control unit side disconnected and the coolant temperature sensor connector
connected, check that the resistance values between pin 13 and the ground lead correspond with the
engine temperature.
20° = 2500 ± 100 Ω
80° = 308 ± 6 Ω
With the connector on the control unit side disconnected and the coolant temperature connector dis-
connected, check the insulation between the light-blue/green cable and ground lead.
Specific tooling
INJEC - 252
BV 350 Injection
Lambda probe
LAMBDA PROBE
Specification Desc./Quantity
1 Lambda probe
2 Injection ECU
PIN RELATIONSHIP
PIN PIN Component Reference value
12 11 Lambda probe ~ 0V with throttle valve closed; ~ 1V with
throttle valve fully opened
The Lambda probe or oxygen sensor is a sensor which provides indications concerning the oxygen
content in the exhaust gas. The signal generated is not of the proportional type but of the ON/OFF type,
i.e. there is oxygen or there is not. The sensor is positioned on the exhaust manifold before the catalytic
converter in an area where the gas temperature is always high. The temperature at which the sensor
works is at least 350°C at 600°C and it has a reaction time of just 50 milliseconds. The signal generated
passes from a high value to a low value with a mixture with lambda =1.
SIGNAL CONTROL
INJEC - 253
Injection BV 350
INJEC - 254
INDEX OF TOPICS
SUSPENSIONS SUSP
Suspensions BV 350
Front
- Remove the wheel axle from the right side, and supporting the wheel, remove it.
See also
Removal
SUSP - 256
BV 350 Suspensions
Specific tooling
001467Y003 Nut
001467Y004 Lug / Taper pin
001467Y005 Screw
001467Y009 Bell for OD 42-mm bearings
SUSP - 257
Suspensions BV 350
Specific tooling
020376Y Adaptor handle
020358Y 37x40-mm Adaptor
020363Y 20-mm guide
- Working on the opposite side of the wheel, insert
the spacer and heat the right bearing seat with the
aid of a heat gun.
Specific tooling
020376Y Adaptor handle
020358Y 37x40-mm Adaptor
SUSP - 258
BV 350 Suspensions
Handlebar
SUSP - 259
Suspensions BV 350
Removal
- Remove the front and rear handlebar covers.
- Unleash the handlebar from the clamps and ca-
ble grommet of the electrical and braking systems.
Refitting
(*) Lubricate the nuts with engine oil before instal-
lation
- Install the handlebar 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.
SUSP - 260
BV 350 Suspensions
- Tighten the handlebar fixing screw on the steering tube to the prescribed torque.
Front fork
SUSP - 261
Suspensions BV 350
Removal
Overhaul
SUSP - 262
BV 350 Suspensions
- Check there are no signs of wear or seizing between the stem and the fork leg. Otherwise, replace
the damaged parts.
Characteristic
Maximum fork leg diameter
1.38in (35.10mm)
Minimum stem diameter
1.3740in (34.90mm)
SUSP - 263
Suspensions BV 350
Specific tooling
020487Y Fork oil seal extractor
Specific tooling
020487Y Fork oil seal extractor
COMPONENT CHECK
CAUTION
CLEAN ALL THE COMPONENTS THOROUGHLY.
SUSP - 264
BV 350 Suspensions
SUSP - 265
Suspensions BV 350
Refitting
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.
SUSP - 266
BV 350 Suspensions
- Refill the fork leg with the recommended product to the prescribed amount.
Recommended products
AGIP FORK 7.5 W Oil for fork.
-
Characteristic
Oil quantity per stem
(7.99±0.183)in (131±3)cc
SUSP - 267
Suspensions BV 350
- 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 picture.
Steering column
SUSP - 268
BV 350 Suspensions
Removal
Specific tooling
020055Y Wrench for steering tube ring nut
See also
Removal
Front handlebar cover
Rear handlebar cover
SUSP - 269
Suspensions BV 350
Refitting
Recommended products
AGIP GREASE PV2 Ivory smooth-textured,
slightly-stringy anhydrous calcium-base
grease.
TL 9150 066, symbol NATO G 460
SUSP - 270
BV 350 Suspensions
Specific tooling
020055Y Wrench for steering tube ring nut
SUSP - 271
Suspensions BV 350
Specific tooling
020055Y Wrench for steering tube ring nut
Steering bearing
SUSP - 272
BV 350 Suspensions
Removal
Specific tooling
020004Y Punch for removing fifth wheels from
headstock
SUSP - 273
Suspensions BV 350
Specific tooling
020004Y Punch for removing fifth wheels from
headstock
SUSP - 274
BV 350 Suspensions
Refitting
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 Ivory smooth-textured,
slightly-stringy anhydrous calcium-base
grease.
TL 9150 066, symbol NATO G 460
Recommended products
SUSP - 275
Suspensions BV 350
Rear
- Carry out the removal operations but in reverse order, observing the prescribed tightening torques.
Swing-arm
Removal
SUSP - 276
BV 350 Suspensions
- It is now possible to remove the swinging arm complete with retainer brackets to the engine.
SUSP - 277
Suspensions BV 350
Overhaul
Specific tooling
020271Y Tool for removing-fitting silent bloc
SUSP - 278
BV 350 Suspensions
Specific tooling
020271Y Tool for removing-fitting silent bloc
Characteristic
Allowable limit after use:
0.0394in (1mm)
Standard clearance
(0.0157÷0.0276)in (0.40÷0.70)mm
SUSP - 279
Suspensions BV 350
Specific tooling
020115Y Ø 18 punch
020244Y 15-mm diameter punch
SUSP - 280
BV 350 Suspensions
Recommended products
AGIP GREASE PV2 Ivory smooth-textured,
slightly-stringy anhydrous calcium-base
grease.
TL 9150 066, symbol NATO G 460
Refitting
- Insert the washers and the rear pin from the right
side of the vehicle and tighten the nut to the speci-
fied torque.
- Insert the pin from the right side of the vehicle and
pretighten the inner nut to the chassis, on the left
side.
SUSP - 281
Suspensions BV 350
SWINGING ARM
Name Torque in Nm
Self-locking retainer nut M10 upper pin (left side) (50.15÷55.32)lb ft (68÷75)Nm
Self-locking retainer nut M10 bottom lower silent block support (36.88÷40.57)lb ft (50÷55)Nm
bracket
Self-locking retainer nut M10 pin (right side) (30.24÷33.19)lb ft (41÷45)Nm
Self-locking retainer nut M10 motor attachment (right side) (40.57÷44.25)lb ft (55÷60)Nm
Retainer nut of silent block support bracket (left side) (65.64÷79.66)lb ft (89÷108)Nm
Lower pin bushing (3.76÷5.09)lb ft (5.1÷6.9)Nm
Shock absorbers
Removal
SUSP - 282
BV 350 Suspensions
See also
Side fairings
Exhaust assy. Removal
Rear mudguard
Refitting
- Execute the removal procedures of the rear shock absorber in reverse order.
- Tighten screws and nuts to the required tightening torque.
Exhaust bracket
Removal
- Before dismantling, secure the vehicle on the centre stand, on a flat surface.
SUSP - 283
Suspensions BV 350
SUSP - 284
BV 350 Suspensions
SUSP - 285
Suspensions BV 350
Overhaul
Plate disassembly
- Working on the outside, remove the snap ring.
- Adequately support the exhaust mounting brack-
et.
- By means of a specific punch, remove the bear-
ing from the seat.
Specific tooling
020359Y 42x47-mm Adaptor
020376Y Adaptor handle
020439Y 17-mm guide
Plate reassembly
- By means of a heat gun, heat the bearing seat
and, through specific punch, insert a new one into
the seat.
- Working on the outside, insert the snap ring
Specific tooling
020151Y Air heater
Refitting
To refit, carry out the removal operations in reverse order, observing the prescribed tightening torques.
N.B.
THE SILENCER SUPPORT ARM MUST BE TIGHTENED AFTER TIGHTENING THE WHEEL.
Locking torques (N*m)
Shock absorber mounting bracket fixing (14.75÷17.70)lb ft (20÷24)Nm M16x13 wheel retaining
nut (75.23÷91.46)lb ft (102÷124)Nm
SUSP - 286
BV 350 Suspensions
Centre-stand
- Unscrew the nut and the pin from the right side.
- Remove the centre stand.
- During refitting, tighten the nut to the specified
torque.
Side stand
SUSP - 287
INDEX OF TOPICS
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. UNDER NORMAL DRIVING AND CLIMATIC CONDITIONS YOU SHOULD CHANGE
THE FLUID EVERY TWO YEARS. IF BRAKES ARE USED INTENSELY AND/OR IN HARSH CON-
DITIONS, 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 SURROUND-
ING AIR.
IF THE MOISTURE CONTENT IN THE BRAKE FLUID EXCEEDS A CERTAIN VALUE, IT WILL RE-
SULT 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 PRO-
TECTIVE DEVICE IS ALLOWED.
WARNING
THE PRESENCE OF BRAKE FLUID ON THE DISC OR BRAKE PADS REDUCES BRAKING EFFI-
CIENCY. IN THIS CASE, REPLACE THE PADS AND CLEAN THE DISC WITH A HIGH-QUALITY
SOLVENT.
Removal
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
Medium Loctite 243 threadlock
Removal
Refitting
- To fit the calliper, follow the above operations but in reverse order.
Removal
See also
Refitting
- Tighten the screws to the prescribed torque and apply the recommended product.
Recommended products
Loctite 243 Medium-strength threadlock
Medium Loctite 243 threadlock
Disc Inspection
Characteristic
New rear disc thickness
0.157in (4.0mm)
Disc thickness at wear limit (rear)
0.138in (3.5mm)
Characteristic
Max. axial run-out
0.00394in (0.1mm)
Removal
See also
Removing the front wheel
Refitting
For fitting, position the disc correctly using the arrow stamped on it as reference.
- Position the collars and washers.
- Do up the screws to the prescribed torque and apply the recommended product
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
Medium Loctite 243 threadlock
Disc Inspection
Characteristic
Thickness of a new front disc
0.157in (4.0mm)
Disc thickness at wear limit (front)
0.138in (3.5mm)
Characteristic
Max. axial run-out
0.00394in (0.1mm)
Removal
Proceed as follows:
- Remove the front brake calliper.
- Unscrew the screws of the fixing pin of the 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 re-
sidual thickness if the brake pad has not worn
evenly. A 0.0197in (0.5mm) thickness difference
in the residual friction material is permitted.
Characteristic
Minimum value
0.0197in (1.5mm)
See also
Front
brake calliper
Refitting
Recommended products
Loctite 243 Medium-strength threadlock
Medium Loctite 243 threadlock
Removal
See also
Removal
Refitting
Recommended products
Loctite 243 Medium-strength threadlock
Medium Loctite 243 threadlock
Fill
Rear - combined
- 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 OBSERVE THIS PRECAUTION WILL ENDANGER THE PROPER WORKING
AND EFFICIENCY OF THE BRAKING SYSTEM
Specific tooling
020329Y Mity-Vac vacuum-operated pump
Front
- 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 OBSERVE THIS PRECAUTION WILL ENDANGER THE PROPER WORKING
AND EFFICIENCY OF THE BRAKING SYSTEM
Specific tooling
020329Y Mity-Vac vacuum-operated pump
Removal
Refitting
Removal
Refitting
Circuit diagram
KEY
A = Expansion tank
B = Radiator
C = Water pump
D = Cylinder
E = Cylinder head
F = Thermostat
G = Breather
TECHNICAL SPECIFICATIONS
Specification Desc./Quantity
Cooling system capacity ~0.53USgal (~0.44UKgal)(~2 l)
Recommended fluid AGIP PERMANENT SPEZIAL (ready for use)
Sealing pressure Cover set to 15.95PSI (110kPa) (1.1 bar)
THERMOSTAT
Specification Desc./Quantity
Type Wax-type, with deviator
Starts opening at 185±35.6°F(85±2°C)
ELECTRIC VENTILATION
Specification Desc./Quantity
Electric ventilation starts at 221°F (105°C)
Electric ventilation stops at 212°F(100°C)
WATER PUMP
Specification Desc./Quantity
Type Centrifugal
Control Electric, commanded by the control unit
RADIATOR
Specification Desc./Quantity
Type Aluminium, with horizontal circulation
EXPANSION TANK
Specification Desc./Quantity
Calibration Automatic bleeding, in parallel with the radiator
CAUTION
BE CAREFUL NOT TO REVERSE THE EXPANSION TANK PIPES. AT HIGH ENGINE SPEED, THE
AIR CONTAINED IN THE TANK MAY ENTER INTO CIRCULATION, RUNNING THE RISK OF THE
ENGINE SEIZING UP.
Characteristic
Battery voltage
12V
WARNING
TO INDICATE THE SOLENOID OF THE DESIRED FUNCTION, REFER TO THE PIN-CABLE COL-
OUR RELATIONSHIP WITH THE ATTACHED ELECTRIC SYSTEM DIAGRAM.
- In order to check the coolant temperature sensor, see the «Injection» chapter.
See also
Remote controls check
System bleed
Thermostat
Removal
Check
Specific tooling
THERMOSTAT
Specification Desc./Quantity
Type Wax-type, with deviator
Starts opening at 185±35.6°F(85±2°C)
Refitting
- Follow the removal steps but in reverse order; be careful to tighten screws to the prescribed torque.
CHASSIS CHAS
Chassis BV 350
This section è is dedicated to the operations that can be carried out on the vehicle's bodywork.
Seat
Rear rack
CHAS - 308
BV 350 Chassis
CHAS - 309
Chassis BV 350
CHAS - 310
BV 350 Chassis
Instrument panel
CHAS - 311
Chassis BV 350
See also
Rear handlebar cover
See also
Rear handlebar cover
CHAS - 312
BV 350 Chassis
Headlight assy.
See also
Rear handlebar cover
Legshield
Legshield
CHAS - 313
Chassis BV 350
See also
Frame central cover
CHAS - 314
BV 350 Chassis
Knee-guard
CHAS - 315
Chassis BV 350
See also
Legshield
See also
Legshield
CHAS - 316
BV 350 Chassis
See also
Legshield
See also
Legshield
CHAS - 317
Chassis BV 350
See also
Knee-guard
See also
CHAS - 318
BV 350 Chassis
Knee-guard
See also
Knee-guard
See also
Removing the ignition key-switch when on *off*
CHAS - 319
Chassis BV 350
See also
Knee-guard
Taillight assy.
See also
Side fairings
CHAS - 320
BV 350 Chassis
Footrest
PASSENGER FOOTREST
To remove the passenger footrests, work on both
sides, as described:
- lower the passenger footrest and unscrew.
RIDER FOOTREST
- It is possible to remove in the same way the rider
footrests, by loosening the two footrest fixing cov-
ers.
Side fairings
CHAS - 321
Chassis BV 350
See also
Footrest
CHAS - 322
BV 350 Chassis
SIDE FAIRING
The following operations are described for just
one, but apply to both the fairings.
- Remove the rear central cover.
- Remove the saddle.
- Remove the lower side fairing
- Undo the three screws.
CHAS - 323
Chassis BV 350
See also
Seat
Rear rack
Side fairings
FRONT FAIRING
- First, remove the lower side fairings and the rider
footrests.
- Unscrew and remove the four screws.
CHAS - 324
BV 350 Chassis
See also
Helmet bay
Air filter
CHAS - 325
Chassis BV 350
Rear mudguard
CHAS - 326
BV 350 Chassis
CHAS - 327
Chassis BV 350
Helmet bay
CHAS - 328
BV 350 Chassis
See also
Side fairings
CHAS - 329
Chassis BV 350
CHAS - 330
BV 350 Chassis
See also
Side fairings
Removing system components
Roll-over valve check
Safety valve check
Canister inspection
Refitting system components
CHAS - 331
Chassis BV 350
See also
Rear rack
Front mudguard
CHAS - 332
BV 350 Chassis
Radiator fan
RADIATOR REMOVAL
- Remove the internal shield in advance.
- Unscrew and remove the two fixing screws and
their washers.
CHAS - 333
Chassis BV 350
CHAS - 334
BV 350 Chassis
See also
Front wheel housing
See also
Front wheel housing
CHAS - 335
Chassis BV 350
See also
Front wheel housing
See also
Front wheel housing
Expansion tank
CHAS - 336
BV 350 Chassis
See also
Knee-guard
Legshield
Flyscreen
CHAS - 337
Chassis BV 350
Battery
Characteristic
Battery
SEALED 12V/10Ah
CHAS - 338
INDEX OF TOPICS
PRE-DELIVERY PRE DE
Pre-delivery BV 350
Aesthetic inspection
Appearance check:
- Paintwork
- Fitting of plastics
- Scratches
- Dirt
FRONT SUSPENSION
FRONT BRAKE
REAR SUSPENSION
REAR BRAKE
STAND
ELECTRICAL SYSTEM
PRE DE - 340
BV 350 Pre-delivery
BODYWORK
Electrical system
• Battery
• Main switch
• Lights: high beam lights, low beam lights, taillights (front and rear) and relevant warning lights
- Headlight adjustment according to the regulations currently in force
• Front and rear stop light buttons and bulb
• Turn indicators and their warning lights
• Instrument lighting
• instruments: fuel and temperature indicator
•Instrument panel lights
• Horn
• Electric starter
• Engine stopping with emergency stop switch
• electric saddle opening button
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 THE LIFE OF THE BATTERY.
CAUTION
WHEN INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEG-
ATIVE ONE.
WARNING
BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SUL-
PHURIC ACID. AVOID CONTACT WITH YOUR EYES, SKIN AND CLOTHING.
IN CASE OF CONTACT WITH YOUR EYES OR SKIN, RINSE WITH ABUNDANT WATER FOR
ABOUT 15 MINUTES AND SEEK IMMEDIATE MEDICAL ATTENTION.
IF IT ACCIDENTALLY SWALLOWED, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR
VEGETABLE OIL. SEEK IMMEDIATE MEDICAL ATTENTION.
BATTERIES PRODUCE EXPLOSIVE GASES; 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:
PRE DE - 341
Pre-delivery BV 350
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
Functional inspection
Functional Checks:
• Hydraulic braking system: lever travel
• Clutch: proper functioning check
• Engine: proper general functioning and no abnormal noise check
• Other: papers check, chassis and engine number check, tools and equipment, licence plate fitting,
lock check, tyre pressure check, rear-view mirror and any accessory fitting
PRE DE - 342
BV 350 Pre-delivery
Instruments start-up
A = Clock
B = «SERVICE» icon
C = Kilometre-mile indicator
D = State of battery charge icon
E = Odometer indicator, partial odometer I and II,
state of battery charge and cyclically selectable
ambient temperature with the «MODE» button
F = Ambient temperature indicator in degrees Cel-
sius or Fahrenheit
G = Indicator «ODO», «ODO I» or «ODO II»
H = Low ambient temperature icon
SELECT MILES - KM
When using the function measuring the voltage of
the battery, holding down the MODE button for
longer than 10 seconds will switch between read-
ing in kilometres or miles for the odometer.
For the first 5 seconds the bearing will not give any
signal, for the next 5 seconds the message of the
unit of measurement (Km or miles) currently in use
will blink at a frequency of 1Hz. If the button is re-
PRE DE - 343
Pre-delivery BV 350
PRE DE - 344
A
Air filter: 49, 325
B
Battery: 86, 97, 108, 109, 338
Brake: 289–291, 293–296, 298, 299
Brake fluid: 298
Bulbs:
C
Checks: 91
Coolant: 252
E
Electric: 303
Engine oil: 50
F
Fuel: 234, 242
Fuses: 106
H
Headlight: 55, 313
Horn: 103
Hub oil: 47
I
Identification: 8
Instrument panel: 72, 311
M
Maintenance: 7, 46
O
Oil filter: 51
R
Recommended products:
S
Shock absorbers: 282
Spark plug: 47, 96
Stand: 287
Start-up: 343
Suspension: 65, 66
T
Tank: 336
Transmission: 9, 64, 134, 161
Turn indicators: 90
Tyres: 10
V
Vehicle: 8, 125, 127