APRILIA scarabeo 125 i.e. Service Station Manual
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APRILIA scarabeo 125 i.e. Service Station Manual

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art vandelay reyiz, xmax kulübünden yılmaz ve erjan reyiz, tüm varyatör
alemi ve scarabeo dostlarına
selamlarımla.
unitekno
SERVICE STATION MANUAL
SCARABEO 125 i.e. - 200 i.e.
854291

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Summary of Contents for APRILIA scarabeo 125 i.e.

  • Page 1 art vandelay reyiz, xmax kulübünden yılmaz ve erjan reyiz, tüm varyatör alemi ve scarabeo dostlarına selamlarımla. unitekno SERVICE STATION MANUAL 854291 SCARABEO 125 i.e. - 200 i.e.

  • Page 2: The Value Of Service

    The descriptions and illustrations given in this publication are not binding; While the basic characteristics as described and illustrated in this booklet remain unchanged, aprilia 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.
  • Page 3 - This manual provides the main information to carry out regular maintenance operations on your vehicle. - This manual is intended to aprilia Dealers and their qualified mechanics; several concepts have been deliberately omitted as they are considered unnecessary. As it is not possible to include complete mechanical notions in this manual, users should have basic mechanical knowledge or minimum knowledge about the procedures involved when repairing scooters.

  • Page 5: Index Of Topics

    INDEX OF TOPICS CHAR HARACTERISTICS TOOL OOLING MAIN AINTENANCE ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE NGINE INJEC NJECTION SUSP USPENSIONS BRAK SYS RAKING SYSTEM COOL SYS OOLING SYSTEM CHAS HASSIS PRE DE DELIVERY...
  • Page 6 INDEX OF TOPICS CHAR HARACTERISTICS...

  • Page 7: Safety Rules

    SCARABEO 125 i.e. - 200 i.e. Characteristics Rules Safety rules GENERAL PRECAUTIONS AND INFORMATION When repairing, dismantling and reassembling the vehicle, follow the recommendations given below carefully. CAUTION USE OF NAKED FLAMES IS FORBIDDEN DURING ALL TYPES OF OPERATION. BEFORE START- ING ANY MAINTENANCE OPERATION OR INSPECTION ON THE VEHICLE, SWITCH OFF THE ENGINE AND REMOVE THE KEY.
  • Page 8 SCARABEO 125 i.e. - 200 i.e. Characteristics The engine and the components of the exhaust system can get very hot and remain hot for some time even after the engine has been switched off. Before handling these components, make sure that you are wearing insulating gloves or wait until the engine and the exhaust system have cooled down.

  • Page 9: Maintenance Rules

    SCARABEO 125 i.e. - 200 i.e. Characteristics RINSE THEM CAREFULLY WITH WATER FOR FIFTEEN MINUTES, THEN SEE AN EYE SPECIAL- IST AS SOON AS POSSIBLE. IF IT IS ACCIDENTALLY SWALLOWED, DRINK LARGE QUANTITIES OF WATER OR MILK, FOL- LOWED BY MILK OF MAGNESIA OR VEGETAL OIL, AND SEEK MEDICAL ADVICE IMMEDIATE- THE BATTERY RELEASES EXPLOSIVE GASES.
  • Page 10 DO NOT USED COMPRESSED AIR TO CLEAN BEARINGS. NOTE BEARINGS MUST ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE, OTHERWISE, THEY NEED TO BE REPLACED. • Use only ORIGINAL Aprilia SPARE PARTS. • Comply with lubricant and consumables usage guidelines. • Lubricate parts (whenever possible) before reassembling them.
  • Page 11 SCARABEO 125 i.e. - 200 i.e. Characteristics • In presence of dirt, rust, humidity etc., clean the connector's internal parts carefully, using a pressurised air jet. • Ensure that the cables are correctly fastened to the internal connector terminals. NOTE THE TWO CONNECTORS CONNECT ONLY FROM ONE SIDE;...

  • Page 12: Vehicle Identification

    SCARABEO 125 i.e. - 200 i.e. Characteristics Thus, mineral salt deposits formed in the radiator by evaporated water are also minimised and the efficiency of the cooling system is not affected. When the temperature drops below zero degrees centigrade, check the cooling system frequently and add more antifreeze if needed (up to 60% max.).

  • Page 13: Chassis Number

    SCARABEO 125 i.e. - 200 i.e. Characteristics CHASSIS NUMBER The chassis number is stamped on the front frame; to read it, open the glove-box and remove the pro- tection cover. Engine number The engine number is stamped on the rear side, next to the left shock absorber.
  • Page 14 SCARABEO 125 i.e. - 200 i.e. Characteristics Specification Desc./Quantity Gearbox automatic Cooling Forced-circulation air cooling driven by a centrifugal pump Fuel system Electronic injection. Throttle body diffuser Ø 32 mm Fuel Premium unleaded petrol, minimum octane rating of 95 (NORM) and 85 (NOMM) Ignition type Electronic Standard spark plug...

  • Page 15: Chassis And Suspension

    SCARABEO 125 i.e. - 200 i.e. Characteristics BULBS/WARNING LIGHTS Specification Desc./Quantity High-/low-beam bulb 12 V 60/55 W H4 Tail light bulb 12V - 5W Front and rear turn indicator bulbs 12V - 10 W (RY amber bulb) License plate light bulb 12V - 5W Rear daylight running light /stop light bulb 12V - 5/21W...

  • Page 16: Tightening Torques

    SCARABEO 125 i.e. - 200 i.e. Characteristics Specification Desc./Quantity Front wheel rim 2.50 x 16'' Rear wheel rim 3.00 x 16'' Tyres Without inner tube (Tubeless) Front tyre 100/80 - 16'' 50 P Rear tyre 120/80 - 16'' 60 P Front tyre standard inflation pressure 200 kPa (2.0 bar) Rear tyre standard inflation pressure...
  • Page 17 SCARABEO 125 i.e. - 200 i.e. Characteristics HEAD INSTRUMENT PANEL UNIT Name Torque in Nm Screw fixing instrument panel to headlamp panel, top section 1 (0.74 lbf ft) Screw fixing instrument panel to headlamp panel, bottom sec- 2 (1.48 lbf ft) tion Screw fixing instrument panel to headlamp panel, bottom sec- 1 (0.74 lbf ft)
  • Page 18 SCARABEO 125 i.e. - 200 i.e. Characteristics Name Torque in Nm Thermal switch retainer 20 (14.8 lbf ft) ELECTRICAL SYSTEM UNIT Name Torque in Nm M6 screw fixing ignition key lock 10 (7.4 lbf ft) M5 screw fixing screw HV coil to chassis 5 (3.7 lbf ft) M8 fixing screw for horn 20 (14.8 lbf ft)

  • Page 19: Overhaul Data

    SCARABEO 125 i.e. - 200 i.e. Characteristics Name Torque in Nm Crankcase fixing screws - M6x50 (2) 11 Nm (8.11 lbf ft) Crankcase fixing screws - M6x70 (1) 11 Nm (8.11 lbf ft) Ignition cover fixing screws - M6x110 (5) 11 Nm (8.11 lbf ft) Ignition cover fixing screws - M6x140 (1) 11 Nm (8.11 lbf ft)
  • Page 20 SCARABEO 125 i.e. - 200 i.e. Characteristics Products RECOMMENDED PRODUCTS TABLE Product Description Specifications AGIP TEC 4T, SAE 10W-40 Engine oil 10W-40 AGIP GEAR SYNTH SAE 75W-90 Gearbox oil API GL4, GL5 AGIP FORK 7.5W Fork oil AGIP GREASE SM2 Lithium grease with molybdenum for NLGI 2 bearings and other points needing lubri-...

  • Page 21: Index Of Topics

    INDEX OF TOPICS TOOL OOLING...
  • Page 22 SCARABEO 125 i.e. - 200 i.e. Tooling OOLS Stores code Description 020708Y Adaptor for engine support AP8140535 driving pulley lock wrench 020702Y Main shaft bearing punch (15 x 42 x 13) on transmission cover 020700Y Water seal punch AP8140838 Flywheel rotor locking 020707Y Flywheel extractor TOOL - 22...
  • Page 23 SCARABEO 125 i.e. - 200 i.e. Tooling Stores code Description AP8140179 Valve spring compressor AP9100838 Tool for valve pressure plate 020705Y Piston seeger ring fitting 020701Y Punch for bushings 020703Y Clutch shaft support bearing punch (15x35x11) on crankcase cover 0240880 Threaded bolt for locking crankshaft at 020704Y Extractor for bushings...
  • Page 24 SCARABEO 125 i.e. - 200 i.e. Tooling Stores code Description AP8140259 Tool for fitting/ removing the driven pulley clutch AP8140665 Adapter for clutch assembly removal AP8140266 Comparator door 020074Y Support base for checking crankshaft alignment 020359Y 42 x 47-mm adaptor 020360Y 52 x 55-mm adaptor TOOL - 24...
  • Page 25 SCARABEO 125 i.e. - 200 i.e. Tooling Stores code Description 020364Y 25 mm Adaptor 020376Y Adapter handle 020439Y Shaft 2 oil seal punch 17 mm 020455Y 10-mm guide for oil seal on water pump shaft 020456Y 24 mm punch 020335Y Magnetic mounting for dial gauge TOOL - 25...
  • Page 26 SCARABEO 125 i.e. - 200 i.e. Tooling Stores code Description 020375Y 28x30 mm punch AP8140662 Punch for roller casing AP8140664 Guide to mount the movable driven pulley AP8140187 Engine support stand 002095Y Engine support 020331Y Digital multimeter TOOL - 26...
  • Page 27 SCARABEO 125 i.e. - 200 i.e. Tooling Stores code Description AP0277512 Fitting buffer AP8104517 Belt removal kit AP8140196+AP8140578 Plurigas (AP8140196 in Italian, AP8140578 in English) 020680Y TXB Navigator TOOL - 27...

  • Page 28: Maintenance

    INDEX OF TOPICS MAIN AINTENANCE...

  • Page 29: Maintenance Chart

    SCARABEO 125 i.e. - 200 i.e. Maintenance Maintenance chart OUTINE MAINTENANCE TABLE I: INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY C: CLEAN, R: REPLACE, A: ADJUST, L: LUBRICATE * Check level every 3,000 km ** Replace every 2 years *** Replace every 4 years km x 1,000 Driven pulley roller casing...
  • Page 30 SCARABEO 125 i.e. - 200 i.e. Maintenance For removal and cleaning: CAUTION BEFORE CARRYING OUT THE FOLLOWING OPERATIONS AND IN ORDER TO AVOID BURNS, LEAVE ENGINE AND SILENCER TO COOL OFF TO AMBIENT TEMPERATURE. • Remove the tube «1» of the spark plug «2».
  • Page 31 SCARABEO 125 i.e. - 200 i.e. Maintenance USE ONLY THE RECOMMENDED TYPE OF SPARK PLUG, OTHERWISE, ENGINE DURATION AND PERFORMANCE COULD BE COMPROMISED. Characteristic Standard spark plug NGK PMR9B Spark plug electrode gap 0.7 - 0.8 mm Locking torques (N*m) Spark plug (1) 10 Nm (7.38 lbf ft) •...
  • Page 32 SCARABEO 125 i.e. - 200 i.e. Maintenance • Check that the quantity is within the specified limits (SEE TECHNICAL DATA), top-up with the necessary quantity if required • Tighten the drain screw «2». • Fill the oil crankcase. • Screw the plug «1». CAUTION DO NOT RIDE THE MOTORCYCLE WITH INSUFFICIENT LUBRICATION OR WITH CONTAMINA- TED OR INCORRECT LUBRICANTS AS THIS ACCELERATES THE WEAR AND TEAR OF THE...

  • Page 33: Air Filter

    SCARABEO 125 i.e. - 200 i.e. Maintenance • Pour approx. 200 cm³ (12.21 cu.in) transmission oil through the fill open- ing. • Screw and tighten the plug «1». Air filter Remove the cover in order to clean the filtering el- ement.
  • Page 34 SCARABEO 125 i.e. - 200 i.e. Maintenance WAIT SOME MINUTES UNTIL THE ENGINE AND THE EXHAUST SYSTEM ARE COLD. • Stop the engine and let it cool off so that the oil in the crankcase flows down and cools as well. •...
  • Page 35 SCARABEO 125 i.e. - 200 i.e. Maintenance • Stop the engine and let it cool down. This will allow the oil to settle into the crankcase and cool down. NOTE FAILURE TO FOLLOW THESE OPERATIONS MAY RESULT IN AN INCORRECT READING OF THE ENGINE OIL LEVEL.

  • Page 36: Cooling System

    SCARABEO 125 i.e. - 200 i.e. Maintenance Transmissions Throttle grip adjustment The empty travel of the throttle grip should be 2-3 mm (0.08-0.12 in), measured at the throttle trim. If this is not so, proceed as follows: • Park the vehicle on its centre stand. •...
  • Page 37 SCARABEO 125 i.e. - 200 i.e. Maintenance • Open the glove-box. • Make sure that the coolant level in the expansion tank «2» is between the «MIN» and «MAX» reference marks. MIN = minimum level. MAX = maximum level. Otherwise, top-up. RADIATOR LEVEL CHECK: •...

  • Page 38: Braking System

    SCARABEO 125 i.e. - 200 i.e. Maintenance • Do not exceed this level. Otherwise, the coolant will spill out when the engine is running. • Refit the filler cap «1». CAUTION IF THERE IS AN EXCESSIVE CONSUMPTION OF COOLANT OR WHEN THE EXPANSION TANK REMAINS EMPTY, CHECK THAT THERE ARE NO LEAKS IN THE CIRCUIT.
  • Page 39 SCARABEO 125 i.e. - 200 i.e. Maintenance Level check • Park the vehicle on its centre stand. • Turn the handlebar so that the fluid in the brake fluid reservoir is parallel to the «MIN» reference mark indicated on the sight glass «1». •...

  • Page 40: System Check

    SCARABEO 125 i.e. - 200 i.e. Maintenance System check NOTE THE FOLLOWING INFORMATION REFERS TO ONE BRAKING CIRCUIT BUT APPLIES TO BOTH. To carry out a quick pad check: • Park the vehicle on its centre stand. • Visually check the brake disc and pads, as indicated below. Front brake callipers From the front bottom side for both pads.
  • Page 41 SCARABEO 125 i.e. - 200 i.e. Maintenance To adjust the light beam: • Use a screwdriver to operate on the specific screw «1» located below the rear handlebar cover. TIGHTEN the screw (clockwise) to lower the light beam. UNDO the screw (anticlockwise) to raise the light beam.

  • Page 42: Index Of Topics

    INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
  • Page 43 SCARABEO 125 i.e. - 200 i.e. Electrical system Components arrangement ELE SYS - 43...
  • Page 44 SCARABEO 125 i.e. - 200 i.e. Electrical system 1. Start-up relay - Start-up relay resistance, powered: 0 Ohm - Start-up relay resistance, not powered: infinite 2. Horn - Voltage with horn activated: battery voltage - Voltage with horn deactivated: 0 V 3.

  • Page 45: Starter Motor

    SCARABEO 125 i.e. - 200 i.e. Electrical system 5. STARTER MOTOR - Relay voltage powered: battery voltage - Resistance: 0.5 Ohm 6. Taillight - Rear tail light/stop light: 12V - 5W/21W - Rear turn indicator light: 12V - 10 W (RY amber bulb) - License plate light: 12V - 5W 7.
  • Page 46 SCARABEO 125 i.e. - 200 i.e. Electrical system 9. HV coil - Coil primary resistance: 0.5 Ohm - Coil secondary resistance: 3.1 KOhm 10. Fuel Level Sensor Fuel level sensor operation check (removed from the vehicle). RESISTANCE BETWEEN THE CABLES ( ) - CORRECT INDICATION COLOUR Specification...
  • Page 47 SCARABEO 125 i.e. - 200 i.e. Electrical system 12. Battery 12V - 10 Ah XTX12-BS YUASA 13. Auxiliary fuses - 15A fuse: from ignition switch to all light loads, license plate light, blinkers and horn. - 15A fuse: ignition /injection and start-up power supply.
  • Page 48 SCARABEO 125 i.e. - 200 i.e. Electrical system 16. Speed sensor 17. Fall sensor - Horizontal position: 61.9 KOhm - oblique position > 45°: 0 Hom 18. Control unit / throttle body ELE SYS - 48...

  • Page 49: Electrical System Installation

    SCARABEO 125 i.e. - 200 i.e. Electrical system 19. Injector Electric resistance at ambient temperature: 14,5 20. Relay - Fan - Injection - Lights Electrical system installation Motorcycle division The wiring timing is subdivided in two essential sections, as indicated in the figure. 1.

  • Page 50: Front Side

    SCARABEO 125 i.e. - 200 i.e. Electrical system 2. Rear section Front side A - Front headlamp B - Handlebar ELE SYS - 50...
  • Page 51 SCARABEO 125 i.e. - 200 i.e. Electrical system C - Steering 1 - Passage of the cable harnesses through the openings in the handlebar. 2 - The red strap on the cable harness must be aligned with the cable grommet. 3 - The main cable harness must pass behind the metal cable grommet.
  • Page 52 SCARABEO 125 i.e. - 200 i.e. Electrical system ELE SYS - 52...
  • Page 53 SCARABEO 125 i.e. - 200 i.e. Electrical system ELE SYS - 53...
  • Page 54 SCARABEO 125 i.e. - 200 i.e. Electrical system D - Footrest 6 - Battery negative clamp. 7 - Diagnostic connector. 8 - Battery positive clamp ELE SYS - 54...
  • Page 55 SCARABEO 125 i.e. - 200 i.e. Electrical system E - Speed sensor 9 - The cable grommet ring must be inserted in the seat provided on the mudguard. 10 - The cable harness must pass through the metal ring and the pipe must be in the central position ELE SYS - 55...

  • Page 56: Back Side

    SCARABEO 125 i.e. - 200 i.e. Electrical system Back side A - Footrest 1 - All three parts of the cable harnesses in red straps must be fixed to the chassis with clamp. 2 - All three cable harnesses must pass through the throttle grip cables. 3 - The horn terminal must be fixed to the ground on the chassis.
  • Page 57 SCARABEO 125 i.e. - 200 i.e. Electrical system B - Engine 6 - Plastic clamp. 7 - The engine cable harness must pass under the water pipe. 8 - Check the correct connection of the control unit. 9 - The cable harness must be fixed with a clamp. 10 - The rear cable harness must pass through the metal ring.
  • Page 58 SCARABEO 125 i.e. - 200 i.e. Electrical system ELE SYS - 58...
  • Page 59 SCARABEO 125 i.e. - 200 i.e. Electrical system ELE SYS - 59...
  • Page 60 SCARABEO 125 i.e. - 200 i.e. Electrical system C - Right side 15 - Plastic clamp. 16 - The rear cable harness must pass through the metal ring. D - Rear cable harness 17 - Plastic clamp. 18 - Fit the fall sensor with the arrow facing up. ELE SYS - 60...
  • Page 61 SCARABEO 125 i.e. - 200 i.e. Electrical system ELE SYS - 61...
  • Page 62 SCARABEO 125 i.e. - 200 i.e. Electrical system Conceptual diagrams KEY: 1. Multiple connectors 2. Fall sensor 3. ECU diagnosis 4. Electric fan ELE SYS - 62...
  • Page 63 SCARABEO 125 i.e. - 200 i.e. Electrical system 5. Instrument panel 6. "MODE" button 7. Speed sensor 8. Turn indicators 9. Light switch 10.Horn 11.Ignition key 12.Front stop 13.Rear stop 14.horn button 15.Taillight 16.Left rear turn indicator 17.Rear daylight running light /stop light bulb 18.Rear right turn indicator 19.License plate light 20.Light relay...

  • Page 64: Checks And Inspections

    SCARABEO 125 i.e. - 200 i.e. Electrical system 43.Turn indicator switch 44.Headlamp position light 45.Low-/high-beam headlight bulb 46.Front left turn indicator 47.Starter button 48.Mapping switch 49.Side stand switch (optional equipment) 50.Diode and resistance Colour key: Ar Orange Az Sky blue B Blue Bi White G Yellow...
  • Page 65 SCARABEO 125 i.e. - 200 i.e. Electrical system When the vehicle is started and right after the initial check, if there are less than 300 km (200 mi) left to the next Service, the specific icon flashes for 5 seconds. Once the Service mileage has been reached, the icon remains steadily on until Service is reset.
  • Page 66 SCARABEO 125 i.e. - 200 i.e. Electrical system 14.Injector 15.Engine speed sensor negative 16.K line diagnosis 17.- 18.Side stand 19.Light relay 20.Injection load relay 21.Lambda probe heater 22.Coil 23.Double mapping switch 24.Start-up enabling 25.Rollover protection switch 26.Injection ground Dashboard KEY: 1.

  • Page 67: Index Of Topics

    INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
  • Page 68 SCARABEO 125 i.e. - 200 i.e. Engine from vehicle Exhaust assy. Removal EXHAUST SILENCER REMOVAL • Park the vehicle on its centre stand. CAUTION ALLOW ENGINE AND EXHAUST SILENCER TO COOL OFF COMPLETELY. CAUTION EACH TIME THE EXHAUST SYSTEM IS REMOVED, REPLACE THE CONNECTING INTERNAL GRAPHITE SLEEVE OF THE SILENCER TO THE EXHAUST PIPE.
  • Page 69 SCARABEO 125 i.e. - 200 i.e. Engine from vehicle • Unscrew and remove the two nuts on the head exhaust stud bolts. • Retrieve the washers. • Undo and remove the three fixing screws «2». • Remove the exhaust system. Locking torques (N*m) M8 screw fixing silencer to plate 25 (18.5 lbf ft)
  • Page 70 SCARABEO 125 i.e. - 200 i.e. Engine from vehicle • Disconnect the starter motor connec- tions. • Disconnect the water temperature sen- sor connector. • Disconnect the oil pressure sensor connector. • Disconnect the connectors of the fly- wheel pick up and voltage regulator. ENG VE - 70...
  • Page 71 SCARABEO 125 i.e. - 200 i.e. Engine from vehicle • Disconnect the lambda probe connec- tor. • Disconnect the spark plug tube. • Loosen the clamp and disconnect the pipe from the thermostatic valve. • Loosen the clamp and disconnect the bleed pipe from the thermostatic valve to the radiator. •...
  • Page 72 SCARABEO 125 i.e. - 200 i.e. Engine from vehicle • Operating from both sides, undo and remove the shock absorber lower fix- ing screw and collect the nut. • Operating on the right side, undo and remove the engine fixing nut. •...
  • Page 73 INDEX OF TOPICS NGINE...

  • Page 74: Automatic Transmission

    SCARABEO 125 i.e. - 200 i.e. Engine This section describes the operations to be carried out on the engine and the tools required. Automatic transmission Transmission cover • Remove the air duct. • Undo and remove the twelve external screws of the cover. •...
  • Page 75 SCARABEO 125 i.e. - 200 i.e. Engine Air duct filter • Remove the air duct. • Undo and remove the screw of the air- box cover. • Remove the air-box cover. • Remove the air filter. • Proceed to clean or replace the air fil- ter.

  • Page 76: Specific Tooling

    SCARABEO 125 i.e. - 200 i.e. Engine Refitting the driven pulley shaft bearing • Slightly heat the crankcase from the in- side so as not to damage the coated surface. • Insert the bearing in its housing. CAUTION REST THE COVER ON A SUITABLE SURFACE TO AVOID DAMAGING THE COVER COAT.
  • Page 77 SCARABEO 125 i.e. - 200 i.e. Engine • Remove the driven pulley and the driv- ing belt. CAUTION CLEAN THE CLUTCH BELL AS INDICATED IN THE SCHED- ULED MAINTENANCE TABLE. Inspecting the clutch drum - Make sure that the clutch bell is not worn or dam- aged.

  • Page 78: Removing The Clutch

    SCARABEO 125 i.e. - 200 i.e. Engine Admissible limit eccentricity: 0.15 mm Inspecting the clutch - Check the thickness of the clutch mass friction material. - The masses must not show traces of lubricants; otherwise, check the driven pulley unit seals. NOTE UPON RUNNING-IN, THE MASSES MUST EXHIBIT A CEN- TRAL FAYING SURFACE AND MUST NOT BE DIFFERENT...
  • Page 79 SCARABEO 125 i.e. - 200 i.e. Engine AP8140665 Adapter for clutch assembly re- moval Pin retaining collar - Remove the collar with the aid of 2 screwdrivers. - Remove the 3 guide pins and the movable half- pulley. Removing the driven half-pulley bearing - Remove the retainer ring using two flat blade screwdrivers.
  • Page 80 SCARABEO 125 i.e. - 200 i.e. Engine Inspecting the driven fixed half-pulley - Measure the inside diameter of the pulley bush- ing. Characteristic Minimum diameter admitted Ø 40.96 mm Standard diameter Ø 40.965 mm Inspecting the driven sliding half-pulley - Remove the 2 inner sealing rings and the 2 O- rings.
  • Page 81 SCARABEO 125 i.e. - 200 i.e. Engine - To assemble the new ball bearing, insert it fully down in its seat with the specific punch and finally fit the seeger ring. Specific tooling 020375Y 28 x30 mm Punch 020376Y Adapter handle 020439Y 17-mm guide for oil seal Refitting the driven pulley - Check that the faying surfaces of the 2 half-pul-...
  • Page 82 SCARABEO 125 i.e. - 200 i.e. Engine Inspecting the clutch spring - Measure the length of the movable driven half- pulley spring, when unloaded. Characteristic Standard length: (125 cm³) 112.7 mm (200 cm³) 122.7 mm Limit after use: (125 cm³) 108 mm (200 cm³) 118 mm Refitting the clutch - Assemble the spring, clutch and driven pulley.
  • Page 83 SCARABEO 125 i.e. - 200 i.e. Engine Refitting the driven pulley • Place the driven pulley assembly in its position. • Open the driven pulley and insert the belt according to the correct direction of rotation. • Fit the driven pulley plus the belt in their position.

  • Page 84: Removing The Driving Pulley

    SCARABEO 125 i.e. - 200 i.e. Engine Removing the driving pulley • Remove the transmission cover. • Unscrew the fixing nut with the specific tool. Specific tooling AP8140535 driving pulley lock wrench • Remove the fixing nut and collect the washer.
  • Page 85 SCARABEO 125 i.e. - 200 i.e. Engine • Detach the driving belt. • Remove the bushing. • Remove the movable half-pulley, take care that the free rollers fitted on it do not come off. • Remove the support plate and the rel- ative guide sliders.
  • Page 86 SCARABEO 125 i.e. - 200 i.e. Engine Inspecting the rollers case • Check that the internal bushing shown in the figure is not abnormally worn and measure its inside diameter. • Measure the outside diameter of the pulley sliding bushing shown in the fig- ure.
  • Page 87 SCARABEO 125 i.e. - 200 i.e. Engine Refitting the driving pulley • Install the spacer. - Preassemble the movable half-pulley with the roller contrast plate by placing the rollers in their housings with the larger support surface touching the pulley according to the direction of rotation. - Check that the roller contact plate does not show flaws or is damaged on the grooved edge.
  • Page 88 SCARABEO 125 i.e. - 200 i.e. Engine • Fit the fixed driving half-pulley. WHEN FITTING THE FIXED DRIVING HALF-PULLEY, IT MUST BE TOTALLY FREE SO THAT IT IS NOT INCOR- RECTLY TAUTENED. • Fit the washer and tighten the nut. CAUTION CHECK THAT THE WASHER IS ADEQUATELY FITTED BE- FORE TIGHTENING THE NUT.
  • Page 89 SCARABEO 125 i.e. - 200 i.e. Engine • Fit the transmission cover and press it until it stops. • Operating diagonally, tighten the cover external screws (11 screws for 200 cm³ - 12 screws for 125 cm³). • Fit the air duct. Locking torques (N*m) CVT cover EI fixing screws - M6x35 10 Nm (7.38...
  • Page 90 SCARABEO 125 i.e. - 200 i.e. Engine Removing the wheel axle • Remove the hub cover. • Remove the intermediate gear. • Remove the two shim washers from the intermediate gear. • Remove the wheel axle with the gear. • Extract the driven pulley shaft from the bearing.
  • Page 91 SCARABEO 125 i.e. - 200 i.e. Engine Removing the hub bearings - Check the status of the bearings being examined (wear, clearance and noise). Removing the wheel axle bearings • Warm up the crankcase. • Remove the bearing using the specific extractor.
  • Page 92 SCARABEO 125 i.e. - 200 i.e. Engine Inspecting the hub shaft - Check the three shafts for wear or distortions on the toothed surfaces, on the bearing housings and the oil seal positions. - In faults are found, replace the damaged parts. Inspecting the hub cover - Check that the coupling surfaces are not dented or distorted.
  • Page 93 SCARABEO 125 i.e. - 200 i.e. Engine Refitting the wheel axle bearing • Heat up the crankcase using the ther- mal gun. • Place the wheel axle bearing on the crankcase and fit it correctly using the specific tool. Specific tooling 020376Y Adapter handle 020359Y 42 x 47-mm adaptor 020439Y Shaft 2 oil seal punch 17 mm...
  • Page 94 SCARABEO 125 i.e. - 200 i.e. Engine Refitting the hub bearings - Assemble the 3 shafts in the engine crankcase as shown in the figure. ENG - 94...

  • Page 95: Flywheel Cover

    SCARABEO 125 i.e. - 200 i.e. Engine Refitting the ub cover • Fit a new gasket. • Check that the two alignment dowels are adequately positioned. • Place the hub cover. • Tighten the eight screws operating di- agonally. • Fill with hub oil.

  • Page 96: Removing The Stator

    SCARABEO 125 i.e. - 200 i.e. Engine • Remove the flywheel cover. • Remove the gasket. WARNING UPON REFITTING, REPLACE THE GASKET WITH A NEW ONE OF SIMILAR TYPE. FOLLOW THE REMOVAL STEPS BUT IN REVERSE ORDER. Removing the stator •...
  • Page 97 SCARABEO 125 i.e. - 200 i.e. Engine Refitting the stator • Install the stator following the removal steps but in reverse order. • Place the pick-up cable as indicated. WARNING FIT THE PICK-UP FIXING PLATE WITH THE SENSOR FAC- ING THE STATOR. •...

  • Page 98: Removing The Starter Motor

    SCARABEO 125 i.e. - 200 i.e. Engine • Place the water pump shaft with its grooves facing the reference point on the cover. • Refit the cover on the engine taking care the centring pins are adequately positioned. Locking torques (N*m) Ignition cover fixing screws - M6x110 (5) 11 Nm Ignition cover fixing screws - M6x140...
  • Page 99 SCARABEO 125 i.e. - 200 i.e. Engine • Remove the starter motor by sliding it off from one side. Removing the flywheel magneto • Remove the flywheel cover. • Lock the crankshaft with the specific special tool. Specific tooling 0240880 Threaded bolt for locking crankshaft at TDC •...
  • Page 100 SCARABEO 125 i.e. - 200 i.e. Engine • Remove the cotter. Intermediate gear FITTING • Fit the intermediate gear. REMOVAL ENG - 100...
  • Page 101 SCARABEO 125 i.e. - 200 i.e. Engine • Remove the flywheel, the cotter and the freewheel. • Slide off the intermediate gear. See also Removing the flywheel magneto Refitting the free wheel • Fit the cotter in its seat, be careful to position it as indicated in the photo- graph.

  • Page 102: Removing The Rocker-Arms Cover

    SCARABEO 125 i.e. - 200 i.e. Engine Refitting the flywheel magneto • Fit the flywheel paying attention to in- sert the cotter adequately. • Lock the flywheel nut to the prescribed torque. Locking torques (N*m) Rotor TEF fixing screw - M8x25 (1) 25 Nm (18.44 lbf ft) - Loctite 243 Refitting the starter motor...

  • Page 103: Specific Tooling

    SCARABEO 125 i.e. - 200 i.e. Engine Removing the timing system drive • Remove the tappet cover. • Remove the flywheel. • Rotate the crankshaft until the front cyl- inder piston reaches the top dead cen- tre (TDC). • Undo and remove the screw on the crankcase and screw the specific tool to prevent crankshaft rotation.

  • Page 104: Removing The Cam Shaft

    SCARABEO 125 i.e. - 200 i.e. Engine See also Removing the rocker-arms cover Removing the flywheel magneto Removing the cam shaft • Remove the timing system control. • Remove the chain tensioner. • Undo and remove the eight screws. • Remove the cam tower cap.

  • Page 105: Removing The Cylinder Head

    SCARABEO 125 i.e. - 200 i.e. Engine Removing the cylinder head • Remove the camshafts. • Undo and remove the two side screws (1). • Loosen the screws (2- 3) operating di- agonally. • Undo and remove both central short screws (2) and collect the washers.
  • Page 106 SCARABEO 125 i.e. - 200 i.e. Engine • Remove the valve bucket tappets. • Compress the valve spring using the specific tool. Specific tooling AP8140179 Valve spring compressor AP9100838 Tool for valve pressure plate • Remove both cotter pins. • Release the valve springs.
  • Page 107 SCARABEO 125 i.e. - 200 i.e. Engine • Remove the valves. - Remove the oil seals with a pair of pliers. See also Removing the cylinder head Removing the cylinder - piston assy. • Remove the head. • Remove the water delivery sleeve. •...
  • Page 108 SCARABEO 125 i.e. - 200 i.e. Engine • Remove the retainer rings from the pin. • Slide off the pin. • Remove the piston. • Remove the three piston rings. See also Removing the cylinder head Inspecting the small end •...
  • Page 109 SCARABEO 125 i.e. - 200 i.e. Engine Inspecting the wrist pin • Check the pin outside diameter. Characteristic Pin (125 - 200) Minimum diameter: 14.995 mm (0.590 in) Standard diameter: 15.0000 +0/-0.0030 mm (0.00012 in) Inspecting the piston • Measure the pin seat diameter on the piston.
  • Page 110 SCARABEO 125 i.e. - 200 i.e. Engine Maximum piston / cylinder coupling clearance after use (125/200) - top ring: 0.075 mm (0.0029 in) - middle ring: 0.065 mm (0.0025 in) - oil scraper: 0.25 mm (0.0098 in) Standard piston / cylinder coupling clearance (125/200) - top ring: +0.03 / 0.062 mm (0.0012 / 0.0024 in) - middle ring: +0.02 / 0.052 mm (0.0008 / 0.0020 in)

  • Page 111: Sealing Rings

    SCARABEO 125 i.e. - 200 i.e. Engine Inspecting the piston rings SEALING RINGS (125 / 200) Specification Desc./Quantity Compression ring (top) 0.2 / 0.35 mm (0.0079 / 0.014 in) Compression ring (middle) 0.2 / 0.35 mm (0.0079 / 0.014 in) Oil scraper ring 0.2 / 0.7 mm (0.0079 / 0.027 in) Top ring maximum value...

  • Page 112: Base Gasket Selection

    SCARABEO 125 i.e. - 200 i.e. Engine • Rotate the crankshaft up to the TDC (the reversal point of the dial gauge ro- tation). • Lock the crankshaft at TDC using the specific tool. • Calculate the difference between the two measurements: using the chart be- low, identify the thickness of the cylin- der base gasket to be used upon...
  • Page 113 SCARABEO 125 i.e. - 200 i.e. Engine Refitting the piston rings • Place the oil scraper spring on the pis- ton. • Fit the oil scraper ring keeping the gap opposed to the spring union. • Fit the middle piston ring with the iden- tification letter T facing the piston crown.

  • Page 114: Inspecting The Cylinder Head

    SCARABEO 125 i.e. - 200 i.e. Engine Inspecting the cylinder head • Using a trued bar, check that the head surface is not worn or distorted. • Check that the camshaft bushings are not worn. • Check that the head cover surface, the intake manifold and the exhaust manifold are not worn.
  • Page 115 SCARABEO 125 i.e. - 200 i.e. Engine - Measure the sealing surface width on the valve seats. VALVE SEALING SURFACE Specification Desc./Quantity Intake valve - sealing surface (125) 2.30 +/- 0.15 mm (0.0905 +/- 0.0059 in) Intake valve - sealing surface (200) 1.97 +/- 0.15 mm (1.0776 +/- 0.0059 in) Exhaust valve - sealing surface (125/200) 2.95 +/- 0.15 mm (0.1161 +/- 0.0059 in)
  • Page 116 SCARABEO 125 i.e. - 200 i.e. Engine Inspecting the valves • Measure the width of the sealing surface on the valve seats and on the valves themselves. • If the sealing surface on the valve is wider than the specified limit, damaged in one or more points or curved, replace the valve with a new one.
  • Page 117 SCARABEO 125 i.e. - 200 i.e. Engine • Remove the head cover. • Cause the engine to reach the top dead centre and lock it at that position using the specific tool. NOTE FOR AN EASY REFIT, MARK TWO REFERENCES ON THE TIMING CHAIN AND THE GEARS OF THE TIMING SYSTEM IN THE COUPLING AREA.
  • Page 118 SCARABEO 125 i.e. - 200 i.e. Engine • Remove the bucket tappet of the valve in question and read the calibration val- ue for that bowl, found inside the buck- et tappet itself. • Replace the bucket tappet with new one of a size suitable to restore the correct clearance.

  • Page 119: Inspecting The Cam Shaft

    SCARABEO 125 i.e. - 200 i.e. Engine Inspecting the springs and half-cones • Check that the spring upper supporting caps and the cotters show no signs of abnormal wear. • Check the unloaded spring length. Characteristic Valve spring length: 33.24 +/- 0.25 mm (1.3086 +/-0.0098 in) Refitting the valves •...
  • Page 120 SCARABEO 125 i.e. - 200 i.e. Engine 30.864 mm (1.21511 in) • Check that the holes used for timing and their shoulders are not worn. • If values measured are not within the specified limits or there are signs of wear, replace the defective components with new ones.
  • Page 121 SCARABEO 125 i.e. - 200 i.e. Engine • Tighten the four central screws (2 - 3) crosswise. Locking torques (N*m) Head EI fixing screws - M8x166 (4) 25 Nm + 90° (18.44 lbf ft + 90°) • Lastly, tighten the two side screws (1). Locking torques (N*m) Head EI fixing screws (chain side) - M6x130 (2) 11 Nm (8.11 lbf ft) •...
  • Page 122 SCARABEO 125 i.e. - 200 i.e. Engine • Get two Ø 6.3 mm (0.25 in) pins. • Place the pins in their positions on the overhead camshafts. • Tighten the eight screws of the cam tower cap crosswise. Locking torques (N*m) Camshaft support EI fixing screws - M6x40 (8) 10 Nm (7.38 lbf ft) •...

  • Page 123: Crankcase - Crankshaft

    SCARABEO 125 i.e. - 200 i.e. Engine • Remove the pins on the camshafts. • Remove the special crankshaft locking tool. • Tighten the screw on the crankcase. • Check the valve clearance and adjust it if required. • Refit the tappet cover. Specific tooling 0240880 Threaded bolt for locking crankshaft at TDC Locking torques (N*m)

  • Page 124: Removing The Crankshaft

    SCARABEO 125 i.e. - 200 i.e. Engine Removing the crankshaft • Slide off the crankshaft from the fly- wheel side by giving short taps with a rubber hammer. See also Removing the flywheel magneto Intermediate gear Removing the crankshaft bearings •...
  • Page 125 SCARABEO 125 i.e. - 200 i.e. Engine Inspecting the crankshaft alignment • Install the crankshaft on the support and measure the misalignment at the two points indicated in the figure. • Check that the crankshaft cone, the tab fitting, the oil seal flow, the knurling and the threaded tangs are in good working order.
  • Page 126 SCARABEO 125 i.e. - 200 i.e. Engine A = 0.01 mm B = 0.01 mm C = 0.10 mm D = 0.06 mm Inspecting the crankcase halves • Before checking the crankcase halves, thoroughly clean all the surfaces and the oil pipes. •...
  • Page 127 SCARABEO 125 i.e. - 200 i.e. Engine NOTE DO NOT TAKE THE MEASUREMENT ON THE TWO HALF-SHELLS COUPLING SURFACE SINCE THE ENDS ARE RELIEVED TO ALLOW BENDING DURING THE DRIVING OPERATION. Characteristic Ideal lubrication pressure 4 atm Driving depth 0.5 +/-0.1 mm from internal stop Refitting the crankshaft •...

  • Page 128: Oil Pressure Check

    SCARABEO 125 i.e. - 200 i.e. Engine • Place the crankshaft half by giving short taps with a rubber hammer. • Tighten the three screws to the pre- scribed torque. • Trim the gasket protruding from the cyl- inder plane. Locking torques (N*m) Crankcase EI fixing screws - M6x70 (1) 11 Nm...

  • Page 129: Crankshaft Oil Seals

    SCARABEO 125 i.e. - 200 i.e. Engine oil by-pass valve, the oil pump and the crankshaft seals. NOTE THIS CHECK MUST BE CARRIED OUT WITH OIL AT THE CORRECT LEVEL AND WITH AN OIL FILTER IN GOOD CONDITION. Characteristic Oil pressure Minimum pressure admitted at 6000 rpm: 3.5 atm.
  • Page 130 SCARABEO 125 i.e. - 200 i.e. Engine Removal • Drain the engine oil. • Remove the flywheel cover. • Remove the flywheel. • Undo and remove the four screws and remove the plate. • Unscrew and remove the two screws. •...
  • Page 131 SCARABEO 125 i.e. - 200 i.e. Engine • Remove the external driving pin from the oil pump shaft. • Detach the shaft and remove the sec- ond external driving pin as well. • Take out the shaft and collect the com- ponents.
  • Page 132 SCARABEO 125 i.e. - 200 i.e. Engine Measure the distance between the outer rotor and the pump body. Characteristic limit clearance allowed: 0.18 mm Check the rotor axial clearance using a trued bar as reference plane, as shown in the figure. Characteristic Limit value allowed: 0.09 mm...
  • Page 133 SCARABEO 125 i.e. - 200 i.e. Engine • Place the plate and tighten the four screws with Loctite 243 • Fit the flywheel and tighten the nut with Loctite 243 • Refit the flywheel cover. Locking torques (N*m) Oil pump plate EI screws - M5x12 (4) 6 Nm (4.42 lbf ft) - Loctite 243 ENG - 133...

  • Page 134: Index Of Topics

    INDEX OF TOPICS INJEC NJECTION...
  • Page 135 SCARABEO 125 i.e. - 200 i.e. Injection MIU injection system This is an integrated ignition and injection system. Injection is indirect in the manifold through an electro-injector. Injection and ignition are timed on the 4-stroke cycle using a tone wheel keyed onto the crankshaft (24-2 teeth) and a reluctant variation (pick-up) sensor.
  • Page 136 SCARABEO 125 i.e. - 200 i.e. Injection - HV coil - Injector Failures are detected and restored by the diag- nostic tester. In any case, when the fault is no longer present, data storage is automatically wiped clean after 16 cycles of use (cold starting, running at regular en- gine temperature, stop).
  • Page 137 SCARABEO 125 i.e. - 200 i.e. Injection a. Battery voltage b. Blown fuse c. Solenoids d. Connectors B: Chassis ground connection C: Fuel system a. Broken fuel pump b. Dirty fuel filter D: Ignition system a. Faulty spark plug b. Broken coil c.
  • Page 138 6. Adjustable parameters/Fixed parameters Specification Desc./Quantity Aprilia hardware (XXXXXX000) This is the mapping code with the numbers inverted. If there are only zeros, this means that the central unit is blank (no mapping): the suitable mapping should be remotely reloaded...

  • Page 139: Device Status

    SCARABEO 125 i.e. - 200 i.e. Injection DEVICE STATUS Specification Desc./Quantity Engine status (Off/running) Engine off or running Rpm sensor (Synchronised/Not synchron.) Synchronised if the control unit detects a correct synchronisa- tion (by means of the crankshaft rpm detection sensor Idle/full load (on/off) ON if idle functioning Active lambda probe (on/off)

  • Page 140: Troubleshooting Procedure

    SCARABEO 125 i.e. - 200 i.e. Injection The adjustable parameters screen page is used: • to align the throttle position sensor. Throttle position sensor alignment Align the throttle position sensor if the throttle body and/or the control unit should be replaced. •...
  • Page 141 SCARABEO 125 i.e. - 200 i.e. Injection Possible Cause Operation Correctness of the parameters Coolant temperature Intake air temperature Stepper throttle valve position (steps and actual opening) Cleaning the auxiliary air pipe and air filter efficiency throttle valve Engine stops at idle ENGINE DOES NOT HOLD IDLING/ IDLING IS UNSTABLE/ IDLING TOO LOW Possible Cause Operation...
  • Page 142 SCARABEO 125 i.e. - 200 i.e. Injection Exhaust backfires in deceleration EXHAUST BACKFIRING WHEN DECELERATING Possible Cause Operation Faults detected by self-diagnosis Pump relay HV coil Injector Engine speed timing sensor Air temperature Coolant temperature Lambda Probe Correctness of the parameters Throttle valve position sensor Stepper Coolant temperature sensor...

  • Page 143: Fuel Supply System

    SCARABEO 125 i.e. - 200 i.e. Injection Possible Cause Operation Lambda Probe Power to spark plug Spark plug Shielded cap HV Cable HV Coil Intake system Air filter Filter housing (seal) Intake sleeve (seal) Parameter reliability Throttle valve position signal Coolant temperature signal Intake air temperature signal Ignition advance...

  • Page 144: Circuit Diagram

    SCARABEO 125 i.e. - 200 i.e. Injection Circuit diagram key: 1. Fuel tank 2. TBEI screw 3. Clip M6 4. Bushing 5. Fuel collecting rubber ring 6. Fuel cap 7. Fuel pump ring nut 8. Fuel pump gasket 9. Fuel pump 10.Complete fuel pipe 11.Supporting plate 12.Screw...

  • Page 145: Removing The Injector

    SCARABEO 125 i.e. - 200 i.e. Injection Removing the injector • Remove the helmet compartment. • Disconnect the fast-release fitting of the fuel. • Disconnect the fuel injector connector. • Undo and remove the screw. Refitting the injector For refitting, follow the operations in reverse order observing the tightening torque. INJEC - 145...
  • Page 146 SCARABEO 125 i.e. - 200 i.e. Injection Removing the butterfly valve • Remove the helmet compartment. • Cut the clamp. • Release the control unit fixing lever. • Undo and remove the cable grommet fixing screw. • Open the cable grommet fins. •...
  • Page 147 SCARABEO 125 i.e. - 200 i.e. Injection • Loosen the clamp fixing the throttle body manifold to the air filter box. • Remove the MIU control unit connector • Disconnect the throttle grip cables from the throttle body. • Remove the throttle body. Refitting the butterfly valve To refit, carry out the removal operations but in re- verse order, making sure to correctly fit the sleeve...

  • Page 148: Fuel Pump Removal

    SCARABEO 125 i.e. - 200 i.e. Injection Fuel pump and filter check FUEL PUMP REMOVAL • Remove the helmet compartment. • Disconnect the fuel pump connector. • Disconnect the fuel pipe. • Unscrew the ring nut. • Remove the fuel pump together with rubber gasket from the tank.
  • Page 149 SCARABEO 125 i.e. - 200 i.e. Injection • Tighten the ring nut of the fuel pump. • Connect fuel pump pipe and connec- tor. Fuel filter check Disconnect the terminals of the electrical pump Remove the screw indicated in the photograph Remove the clamp fixing the piping to the filter shown in the photograph INJEC - 149...
  • Page 150 SCARABEO 125 i.e. - 200 i.e. Injection Separate the lower part of the pump support as shown in the photograph. Remove the filter from the pump support Zeroing the throttle Throttle valve position signal reset (TPS reset) The MIU control unit is supplied with throttle valve position sensor and is pre-calibrated. Pre-calibration entails regulating the minimum opening of the throttle valve to obtain a specific air flow under pre-set reference conditions.
  • Page 151 SCARABEO 125 i.e. - 200 i.e. Injection Press the + and - keys go to the adjustable parameters screen page and select «TPS RESET» pa- rameter. Specific tooling AP8140595 Axone + battery charger (230V 50Hz) AP8202311 Axone + battery charger (110V 60Hz) 020680Y TXB Navigator Make sure that the throttle valve control is in con- tact with the stop screw.

  • Page 152: Index Of Topics

    INDEX OF TOPICS SUSP USPENSIONS...

  • Page 153: Removing The Front Wheel

    SCARABEO 125 i.e. - 200 i.e. Suspensions Front Removing the front wheel key: 1. Grey front wheel 2. Front wheel axle 3. Tubeless valve 4. Front tyre 5. Front brake disc 6. TE flanged screw M8x30 7. Sealing ring 8. Bearing 9.
  • Page 154 SCARABEO 125 i.e. - 200 i.e. Suspensions Park the vehicle on its centre stand. • Place a support under the chassis. • Loosen the pin locking screw. CAUTION UPON REMOVING/REFITTING, PAY ATTENTION NOT TO DAMAGE THE BRAKE HOSES, DISCS AND PADS. CAUTION DO NOT ACTUATE NEITHER BRAKE LEVER AFTER RE- MOVING THE WHEEL.
  • Page 155 SCARABEO 125 i.e. - 200 i.e. Suspensions • Collect the spacer. Front wheel hub overhaul • Remove the front wheel. • Clean the two sides of the hub with a cloth. • Remove the right oil seal «1». • Remove the right bearing «2» with a suitable extractor.

  • Page 156: Wheel Axle

    SCARABEO 125 i.e. - 200 i.e. Suspensions BEARINGS Manually rotate the internal ring «1» which must turn smoothly, without obstacles and/or noise. There must be no axial clearance. The bearings presenting these problems must be replaced. CAUTION CHECK THAT ALL THE PARTS ARE IN GOOD CONDI- TIONS, SPECIALLY THE ONES BELOW.

  • Page 157: Front Fork

    SCARABEO 125 i.e. - 200 i.e. Suspensions Check the tyre conditions. CAUTION CHECK TYRE TREAD FOR WEAR. BADLY WORN TYRES COMPROMISE TRACTION AND VEHICLE HANDLING. REPLACE TYRES WHEN WORN OR IF THERE IS A PUNC- TURE BIGGER THAN 5 MM IN THE TREAD. SOME TYRE TYPES HOMOLOGATED FOR THIS VEHICLE FEATURE WEAR INDICATORS.
  • Page 158 SCARABEO 125 i.e. - 200 i.e. Suspensions 8. Pumping rod 9. Screw 10. Sliding bushing 11. Oil seal washer 12. Oil seal 13. Retainer ring 14. Dust gaiter 15. Spring 16. Cap 17. O-ring 18. Cap Removal • Hold the front part of the vehicle with a belt and a hoist. •...

  • Page 159: Fork Removal

    SCARABEO 125 i.e. - 200 i.e. Suspensions FORK REMOVAL • Drain off the oil. • Place the stem in a vice fitted with pro- tection shoes (aluminium). • Unscrew and remove the lower screw «1» and collect the washer. • Slide off the stem from the sleeve and collect the bushing.
  • Page 160 SCARABEO 125 i.e. - 200 i.e. Suspensions • Slide off the retainer ring «5» from the sleeve. • Slide off the oil seal «6» from the sleeve. • Slide off the washer 7» from the sleeve. • Slide off the bushing 8» from the sleeve.
  • Page 161 SCARABEO 125 i.e. - 200 i.e. Suspensions • Place the sleeve in a vice. CAUTION THE WHEEL HOLDER STEM SLEEVE UNIT CONTAINS OIL. DO NOT TURN IT OVER OR TILT IT TOO MUCH WHEN REMOVING IT. • Lower the cover «1» until the seeger ring can be removed «2».
  • Page 162 SCARABEO 125 i.e. - 200 i.e. Suspensions • Drain off the oil into the collecting con- tainer by pumping it out with the stem. Overhaul Wheel holder stem • Check the sliding surface for scorings and/or scratches. These scorings can be eliminated by rubbing them with wet sandpaper (dowel 1).
  • Page 163 SCARABEO 125 i.e. - 200 i.e. Suspensions - oil seal «2»; - dust gaiter «3». Refitting • Place the sleeve in the vice fitted with protection jaws (aluminium). • Place the spacer «1». CAUTION BE EXTREMELY CAREFUL SO THAT NO FOREIGN BOD- IES GET INTO THE SLEEVE OR THE WHEEL HOLDER STEM.
  • Page 164 SCARABEO 125 i.e. - 200 i.e. Suspensions • Fit the retainer ring. • Fit the dust gaiter. • Insert the pumping member pin and the spring in the stem. • Insert the stem together with the bush- ing «2» in the sleeve. SUSP - 164...

  • Page 165: Oil Filling

    SCARABEO 125 i.e. - 200 i.e. Suspensions • Tighten the lower screw «3» with washer. • Fill with oil. OIL FILLING • Place the wheel holder stem sleeve unit in a vice fitted with protection shoes (aluminium). • Pour fork oil into the wheel holder stem sleeve unit.

  • Page 166: Steering Bearing

    SCARABEO 125 i.e. - 200 i.e. Suspensions • Fit the cap «1» together with the O- ring. • Lower the cover «1» until the seeger ring can be insert «2». • Fit the seeger ring «2». Steering bearing Check that the ball contact area «1» on the rotating seat «2»...

  • Page 167: Removing The Rear Wheel

    SCARABEO 125 i.e. - 200 i.e. Suspensions Removing the rear wheel key: 1. Rear wheel nut 2. Rear tyre 120/80-16" 3. Grey rear wheel 4. Tubeless valve 5. Brake disc 6. Screw M8x30 7. Outside spacer 8. Int. spacer The procedure to remove the rear wheel is described below sequentially: •...
  • Page 168 SCARABEO 125 i.e. - 200 i.e. Suspensions • Unscrew and remove the two bolts fix- ing the right shock absorber and collect the nuts. • With the help of a second operator, op- erate the rear brake; unscrew and re- move the rear nut fixing the plate, and collect the spacer.

  • Page 169: Shock Absorbers

    SCARABEO 125 i.e. - 200 i.e. Suspensions Shock absorbers Rear suspension check Check that the shock absorbers do not leak. Check the tightening of all the elements and the correct operation of the rear suspension joints. Removal To remove the shock absorbers, proceed as follows: •...
  • Page 170 SCARABEO 125 i.e. - 200 i.e. Suspensions • Working from both sides of the vehicle, undo the lower screw fixing the shock absorbers. • Remove the shock absorbers. Locking torques (N*m) M10 lower screw fixing shock absorber 50 (37 lbf ft) Exhaust bracket To remove the silencer plate, proceed as follows: •...

  • Page 171: Centre-Stand

    SCARABEO 125 i.e. - 200 i.e. Suspensions • Unscrew and remove the two front bolts «1» fixing the plate and collect the nuts and the washers. • Remove the right suspension plate. Locking torques (N*m) Screw fixing the silencer plate to the engine (18.5 lbf ft) Centre-stand CAUTION...

  • Page 172: Index Of Topics

    INDEX OF TOPICS BRAK SYS RAKING SYSTEM...

  • Page 173: Rear Brake Disc

    SCARABEO 125 i.e. - 200 i.e. Braking system key: 1. Oil pipe screw 2. Front brake pipe 3. Washer 4. Rear brake pipe Rear brake disc Removal • Remove the rear wheel. • Undo and remove the five brake disc screws.
  • Page 174 SCARABEO 125 i.e. - 200 i.e. Braking system Disc Inspection • Carry out a visual inspection of brake disc surface. Replace the disc if scored or deteriorated. • Check the brake disc for wear by measuring the minimum thickness with a micrometer at different points.

  • Page 175: Front Brake Pads

    SCARABEO 125 i.e. - 200 i.e. Braking system • Check the brake disc for wear by measuring the minimum thickness with a micrometer at different points. Replace the disc if the minimum thickness, even at a single point of the disc, is less than the minimum value.

  • Page 176: Rear Brake Pads

    SCARABEO 125 i.e. - 200 i.e. Braking system • Unscrew and remove the pad check pin. • Slide the pads off their seats. CAUTION AFTER REMOVING THE PADS, DO NOT OPERATE THE BRAKE LEVER; OTHERWISE, THE CALLIPER PLUNGER COULD GO OUT OF ITS SEAT RESULTING IN BRAKE FLU- ID LEAKAGE.
  • Page 177 SCARABEO 125 i.e. - 200 i.e. Braking system • Slide off the pin. • Remove the spring. CAUTION THE ARROW STAMPED ON THE SPRING MUST ALWAYS BE TURNED IN THE RIDING DIRECTION. • Slide off the brake pads. • Insert the two new brake pads. •...
  • Page 178 SCARABEO 125 i.e. - 200 i.e. Braking system Actuating on the (front) right brake lever, through the brake pipe «1», exerts a pressure on the plung- ers «A» and «C» on the front brake calliper. Actuating on the (rear) left brake lever, through the brake pipe «2», exerts a pressure on the plunger «B»...

  • Page 179: Rear Brake

    SCARABEO 125 i.e. - 200 i.e. Braking system REAR BRAKE • Remove the rubber protection cover of the bleeding valve «4». • Insert a transparent plastic pipe in the bleeding valve «4» of the rear brake calliper and insert the other end of this pipe into a container to collect the fluid.
  • Page 180 SCARABEO 125 i.e. - 200 i.e. Braking system • Check that the fluid flows out of the reservoir and, before the reservoir is drained off, close the bleeding valve «1-2». • Top-up the reservoir. • Loosen the bleeding valve «1-2» ap- proximately half a turn again.
  • Page 181 INDEX OF TOPICS COOL SYS OOLING SYSTEM...

  • Page 182: Coolant Replacement

    SCARABEO 125 i.e. - 200 i.e. Cooling system Circuit diagram key: 1. Expansion tank 2. Expansion tank cap 3. TBEI screw 4. Clip M6 5. Breather pipe 6. Clamp 7. Radiator-exp. tank pipe 8. Breather pipe 9. Head-radiator pipe 10. Clamp 11.

  • Page 183: Water Pump - Overhaul

    SCARABEO 125 i.e. - 200 i.e. Cooling system • Remove the legshield. • Loosen the clamp. • Slide off the pipe. • Drain off the system. NOTE REMOVE THE EXPANSION TANK CAP TO FACILITATE COOLANT DRAINAGE. WARNING SHOULD THE CIRCUIT BE FULLY EMPTIED, LIFT THE FRONT WHEEL AT LEAST 55 cm (21.65 in) FROM THE GROUND.

  • Page 184: Water Pump Check

    SCARABEO 125 i.e. - 200 i.e. Cooling system • Working from the flywheel cover inter- nal side, remove the safety ring. • Working from the flywheel cover inter- nal side, remove the shaft of the pump together with the rotor using a rubber mallet.
  • Page 185 SCARABEO 125 i.e. - 200 i.e. Cooling system WATER PUMP REFITTING • Fit the oil seal working from the fly- wheel cover internal side and using the specific special tool. Specific tooling 020376Y Adapter handle 020456Y 24 mm Ø punch 020455Y 10-mm guide for oil seal on water pump shaft •...
  • Page 186 INDEX OF TOPICS CHAS HASSIS...
  • Page 187 SCARABEO 125 i.e. - 200 i.e. Chassis Seat It is necessary to lift the saddle before removing it. Insert the key in the key lock and turn it clockwise until a click is heard. • Lift the saddle. • Unscrew the four nuts «1». •...

  • Page 188: Instrument Panel

    SCARABEO 125 i.e. - 200 i.e. Chassis In case of accidental shock, the rear-view mirror will turn inwards, reducing the vehicle width. To set the rear-view mirror back in place, turn it in the op- posite direction as far as it will go; If necessary, actuate on the nut «2».
  • Page 189 SCARABEO 125 i.e. - 200 i.e. Chassis • Undo the two screws «2» and remove the upper frame «3». • Undo the three screws «4 and remove the windshield. • Working from both sides, undo the eight screws «5» and remove the rear handle cover.
  • Page 190 SCARABEO 125 i.e. - 200 i.e. Chassis • Remove the rubber protection and dis- connect the connector of the instru- ment panel unit «7». Headlight assy. • Remove the instrument panel. • Undo and remove the two screws «1». • Slide off the bulb holder of the tail light «2», release the connector of the low- beam headlight bulb «3», undo and...
  • Page 191 SCARABEO 125 i.e. - 200 i.e. Chassis Legshield • Unscrew and remove the four screws «1». • Undo and remove the two screws «2». • Slightly lift the shield front section and remove it by sliding it off from the tongues.
  • Page 192 SCARABEO 125 i.e. - 200 i.e. Chassis • Turn the ring nut of the starter switch clockwise and slide it off from that switch. • Undo and remove the four screws «2». • Remove the leg shield back plate. Footrest To remove the footrest, proceed as follows: NOTE THE FOLLOWING OPERATIONS REFER TO ONE SIDE OF THE VEHICLE, BUT APPLY TO BOTH.

  • Page 193: Side Fairings

    SCARABEO 125 i.e. - 200 i.e. Chassis • Undo and remove the screw «1» from both sides. • Undo and remove the three screws «2» and the two screws «3» from both sides. • Undo and remove the two screws «4» located at the bottom of the footrest, from both sides.
  • Page 194 SCARABEO 125 i.e. - 200 i.e. Chassis • Remove the fairing by releasing it from its fixing tongues. CAUTION PROCEED WITH CAUTION. DO NOT DAMAGE THE TABS AND/OR THEIR CORRESPONDING SLOTS. HANDLE PLASTIC AND PAINTED COMPONENTS WITH CARE, DO NOT SCRATCH OR SPOIL THEM.
  • Page 195 SCARABEO 125 i.e. - 200 i.e. Chassis • Remove the air filter box and discon- nect the oil vapour recovery pipe. • Remove the air filter box. Tail guard • Park the vehicle on its centre stand. • Remove the rear luggage carrier. •...

  • Page 196: Rear Mudguard

    SCARABEO 125 i.e. - 200 i.e. Chassis • Disconnect the taillight connector «3» and the connector «4» of the rear indi- cator arrows. • Remove the tail fairing together with the taillight. Rear mudguard To remove the rear mudguard, proceed as follows: •...
  • Page 197 SCARABEO 125 i.e. - 200 i.e. Chassis • Undo and remove the three screws «3». • Disconnect the connector of the li- cense plate holder light and remove the mudguard. Helmet bay • Lift the saddle. • Remove the rear luggage carrier. •...
  • Page 198 SCARABEO 125 i.e. - 200 i.e. Chassis • Undo and remove the two screws «3» and the screw «4». • Release the saddle lock by undoing the two screws «5». • Disconnect the connector of the plug socket on the vehicle left side. •...
  • Page 199 SCARABEO 125 i.e. - 200 i.e. Chassis Fuel tank • Remove the helmet compartment. • Disconnect the fuel pump connector. • Disconnect the fuel pipe. • Remove the gasket from the fuel tank cap. • Release the clamp and disconnect the fuel breather pipe.

  • Page 200: Radiator Fan

    SCARABEO 125 i.e. - 200 i.e. Chassis • Undo and remove the four fuel tank fix- ing screws, collecting the spacers. • Remove the fuel tank. Radiator fan To remove the radiator, proceed as follows: • Empty the cooling system (SEE COOLANT CHANGE).

  • Page 201: Expansion Tank

    SCARABEO 125 i.e. - 200 i.e. Chassis • Remove the blinker devices. • Detach and lift the radiator to release it from its seat. • Disconnect the electric fan connector «3». • Remove the radiator with the expan- sion tank. Expansion tank •...
  • Page 202 INDEX OF TOPICS PRE DE DELIVERY...
  • Page 203 SCARABEO 125 i.e. - 200 i.e. Pre-delivery Carry out the listed checks before delivering the motorcycle. WARNING HANDLE FUEL WITH CARE. Aesthetic inspection - Paintwork - Fitting of Plastic Parts - Scratches - Dirt Tightening torques inspection - Safety fasteners: front and rear suspension unit front and rear brake calliper retainer unit front and rear wheel unit...
  • Page 204 SCARABEO 125 i.e. - 200 i.e. Pre-delivery - Through the diagnosis tool, check that the last mapping version is present in the control unit/s and, if required, program the control unit/s again: consult the technical service website to know about available upgrades and details regarding the operation.

  • Page 205: Static Test

    SCARABEO 125 i.e. - 200 i.e. Pre-delivery - Front and rear brake efficiency - Front and rear suspension efficiency - Abnormal noise Static test Static check after test drive: - Restarting when warmed up - Starter operation (if present) - Minimum holding (turning the handlebar) - Uniform turning of the steering - Possible leaks - Radiator electric fan operation (if present)
  • Page 206 Air filter: 33, 194 Brake: 173–176 Brake disc: 173, 174 Brake pads: 175, 176 Clutch: 77, 78, 82 Connectors: 65 coolant: 182 Coolant: 182 Crankcase: 123, 126, 127 Crankshaft: 123–129 Cylinder: 19, 102, 105, 107, 108, 110, 113, 114 Display: ECU: 65 Electrical system: 14, 43, 49, 203 Engine oil: 33...
  • Page 207 Radiator: 200 Rear wheel: 167 Recommended products: Shock absorbers: 169 Side fairings: 193 Spark plug: 29 Stand: Start-up: Starter motor: 98, 102 Tank: 199, 201 Technical data: Transmission: 14, 74, 88 Tyres: 15 Water pump: 183...

This manual is also suitable for:

Scarabeo 200 i.e.

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