APRILIA SCARABEO 125 Service Manual
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APRILIA SCARABEO 125 Service Manual

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SERVICE STATION MANUAL
854141
SCARABEO 125 - 200

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  • Page 1 SERVICE STATION MANUAL 854141 SCARABEO 125 - 200...
  • Page 2 The descriptions and illustrations given in this publication are not binding; While the basic characteristics as described and illustrated in this manual 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 SERVICE STATION MANUAL SCARABEO 125 - 200 NOTE 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.

  • Page 4: Index Of Topics

    INDEX OF TOPICS CHAR HARACTERISTICS TOOL OOLING MAIN AINTENANCE ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE NGINE SUSP USPENSIONS BRAK SYS RAKING SYSTEM COOL SYS OOLING SYSTEM CHAS HASSIS PRE DE DELIVERY...
  • Page 5 INDEX OF TOPICS CHAR HARACTERISTICS...

  • Page 6: Safety Rules

    SCARABEO 125 - 200 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 7 SCARABEO 125 - 200 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 8: Maintenance Rules

    SCARABEO 125 - 200 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 9 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 10 SCARABEO 125 - 200 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; CONNECT THEM THE RIGHT WAY ROUND.

  • Page 11: Vehicle Identification

    SCARABEO 125 - 200 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 12: Chassis Number

    SCARABEO 125 - 200 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 13 SCARABEO 125 - 200 Characteristics Specification Desc./Quantity Overrevving limit (125 - 200) 10300 Valve clearance Inlet: 0.10 ÷ 0.15 Outlet: 0.15 ÷ 0.20 Valve angle (125 - 200) 15° intake - 18° outlet Combustion chamber volume (125) 11.3 cm³ (0.69 cu.in) Combustion chamber volume (200) 17 cm³...
  • Page 14 SCARABEO 125 - 200 Characteristics Transmission TRANSMISSION Specification Desc./Quantity Transmission (125 - 200) CVT with belt + final reduction unit CVT ratio (125 ) 2.7: 1 - 0.84 1 CVT ratio (200) 2.2: 1 - 0.81: 1 Gear ratio - long pitch (125)

  • Page 15: Wheels And Tyres

    SCARABEO 125 - 200 Characteristics Specification Desc./Quantity Turn indicator warning light (*) High-beam warning light (*) Low fuel warning light (*) (*) Cannot be replaced Frame and suspensions CHASSIS AND SUSPENSIONS Specification Desc./Quantity Chassis type High-strength steel tubular chassis, single spar at the front, su- perimposed double cradle at the rear.
  • Page 16 SCARABEO 125 - 200 Characteristics Name Torque in Nm M5 screw fixing case to wheel housing 4 (2.96 lbf ft) CENTRAL BODYWORK UNIT Name Torque in Nm Footrests to chassis fixing screw 4 (2.96 lbf ft) M6 screw fixing battery access to footrest 4 (2.96 lbf ft)
  • Page 17 SCARABEO 125 - 200 Characteristics ENGINE LINK ROD UNIT Name Torque in Nm M10 screw fixing connecting rod to engine 50 (37 lbf ft) M10 screw fixing connecting rod to timing buffer 50 (37 lbf ft) M12 pin fixing connecting rod to chassis 60 (44.4 lbf ft)
  • Page 18 SCARABEO 125 - 200 Characteristics FRONT SUSPENSION UNIT Name Torque in Nm Steering nut 15 (11.1 lbf ft) unscrew ¼ of a turn Steering lock nut 110 (81.4 lbf ft) M6 screw fixing front wheel axle clamp 10 (7.4 lbf ft)
  • Page 19 SCARABEO 125 - 200 Characteristics Product Description Specifications AGIP GREASE SM2 Lithium grease with molybdenum for NLGI 2 bearings and other points needing lubri- cation AGIP BRAKE 4 Brake fluid FMVSS DOT4+ AGIP PERMANENT SPEZIAL Coolant Biodegradable coolant, ready for use, with "long life"...

  • Page 20: Index Of Topics

    INDEX OF TOPICS TOOL OOLING...
  • Page 21 SCARABEO 125 - 200 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...
  • Page 22 SCARABEO 125 - 200 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...
  • Page 23 SCARABEO 125 - 200 Tooling Stores code Description AP8140259 Tool for fitting/removing the clutch on the driven pulley AP8140665 Adapter for clutch assembly removal AP8140266 Comparator door 020074Y Support base for checking crankshaft alignment 020359Y 42 x 47-mm adaptor 020360Y...
  • Page 24 SCARABEO 125 - 200 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 Dial gauge magnetic support...
  • Page 25 SCARABEO 125 - 200 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 - 25...
  • Page 26 SCARABEO 125 - 200 Tooling Stores code Description AP0277512 Fitting buffer AP8104517 Belt removal kit AP8140196+AP8140578 Plurigas (AP8140196 in Italian, AP8140578 in English) TOOL - 26...

  • Page 27: Maintenance

    INDEX OF TOPICS MAIN AINTENANCE...

  • Page 28: Maintenance Chart

    SCARABEO 125 - 200 Maintenance Maintenance chart 1000 FTER Action Safety locks - check Throttle lever - adjustment Engine oil filter - replacement Electrical system and battery - Check Coolant level - check Brake fluid level - check Engine oil - change...

  • Page 29: Every 2 Years

    SCARABEO 125 - 200 Maintenance Action Throttle lever - adjustment Air filter - cleaning Air filter belt compartment - Check and cleaning Engine oil filter - replacement Valve clearance - check Electrical system and battery - Check Coolant level - check...

  • Page 30: Spark Plug

    SCARABEO 125 - 200 Maintenance Spark plug • Lift the saddle. • Unscrew and remove the two screws «3» (one at each side). • Unscrew and remove the two screws «4» (one at each side). CAUTION PROCEED WITH CAUTION. DO NOT DAMAGE THE LOWER FIXING TABS AND/OR THEIR CORRESPONDING SLOTS.
  • Page 31 SCARABEO 125 - 200 Maintenance Check NOTE USE RECOMMENDED OIL ONLY. REFER TO THE RECOMMENDED PRODUCTS TABLE. • Park the vehicle on firm and level ground. • Park the vehicle on its centre stand. To check hub oil level, drain off the crankcase and measure the oil level in a suitable container.

  • Page 32: Air Filter

    SCARABEO 125 - 200 Maintenance • Park the vehicle on its centre stand. CAUTION WAIT SOME MINUTES UNTIL THE ENGINE AND THE EXHAUST SYSTEM ARE COLD. • Unscrew and extract the plug «1». • Place a collecting container with 200 cm³...

  • Page 33: Engine Oil

    SCARABEO 125 - 200 Maintenance • Remove the filter box cover together with the filtering element. • Check the filtering element, and re- place it if necessary. Cleaning CAUTION USE COMPRESSED AIR ONLY. CLEAN THE FILTERING ELEMENT WITH A JET OF COMPRESSED AIR.
  • Page 34 SCARABEO 125 - 200 Maintenance • Place a collecting container under the oil drainage plug «4». • Unscrew and remove the oil drainage plug «4» and then drain all the engine oil into the collecting container. • Remove the cover by undoing the 2 screws «3»...
  • Page 35 SCARABEO 125 - 200 Maintenance • Stop the engine and let it cool off so that the oil in the crankcase flows down and cools as well. NOTE FAILURE TO FOLLOW THESE OPERATIONS MAY RE- SULT IN AN INCORRECT READING OF THE ENGINE OIL LEVEL.

  • Page 36: Cooling System

    SCARABEO 125 - 200 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 - 200 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 - 200 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 - 200 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 - 200 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.
  • Page 41 SCARABEO 125 - 200 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 - 200 Electrical system Components arrangement ELE SYS - 43...
  • Page 44 SCARABEO 125 - 200 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. Headlamp...

  • Page 45: Starter Motor

    SCARABEO 125 - 200 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...
  • Page 46 SCARABEO 125 - 200 Electrical system 9. HV coil - Coil primary resistance: 0.5 Ohm - Coil secondary resistance: 8.1 kOhm 10. Fuel Level Sensor Fuel level sensor operation check (removed from the vehicle). RESISTANCE BETWEEN THE CABLES ( ) - CORRECT INDICATION...
  • Page 47 SCARABEO 125 - 200 Electrical system 13. Auxiliary fuses - 15A fuse: from ignition switch to all light loads, license plate light, blinkers and horn. - 15A fuse: from ignition switch to plug socket. - 15A fuse: spare part. 14. Generator - Permanent magnet: battery voltage 12 V - 221 W at 6000 rpm.

  • Page 48: Electrical System Installation

    SCARABEO 125 - 200 Electrical system Electrical system installation Front side • Lay and fasten the cable harness with a clamp as indicated in the picture. CAUTION THE CABLE HARNESS MAY GET DAMAGED IF IT IS IN- CORRECTLY LAID. See also...
  • Page 49 SCARABEO 125 - 200 Electrical system Conceptual diagrams ELE SYS - 49...
  • Page 50 SCARABEO 125 - 200 Electrical system 1. Multiple connectors 2. Light switch 3. "MODE" Button 4. Speed sensor 5. Instrument panel - Oil warning light (Pin 1) - "MODE" button (Pin 2) - Left turn indicator input (Pin 3) - Right turn indicator input (Pin 4)

  • Page 51: Cable Colours

    SCARABEO 125 - 200 Electrical system 24. Side stand switch pre-installation 25. Coil 26. Spark plug 27. Control unit 28. Pick-up 29. Flywheel 30. Voltage regulator 31. Starter motor 32. Start-up relay 33. Battery 34. Main fuse 35. Auxiliary fuses 36.
  • Page 52 SCARABEO 125 - 200 Electrical system Ignition 9. Key switch 18. Engine stop switch 23. Ignition relay 24. Side stand switch pre-installation 25. Coil 26. Spark plug 27. Control unit 33. Battery 34. Main fuse ELE SYS - 52...
  • Page 53 SCARABEO 125 - 200 Electrical system Battery recharge and starting 9. Key switch 10. Front stop 11. Rear stop 14. Starter button 18. Engine stop switch 20. Rear tail light/ stop light 23. Ignition relay 24. Side stand switch pre-installation 27.
  • Page 54 SCARABEO 125 - 200 Electrical system Level indicators and enable signals section 4. Speed sensor 5. Instrument panel - Oil warning light (Pin 1) - Sensor ground lead (Pin 7) - Speed sensor ground lead (Pin 8) - Speed sensor power supply (Pin 10)

  • Page 55: Devices And Accessories

    SCARABEO 125 - 200 Electrical system 37. Oil sensor 38. Water sensor 39. Fuel level sensor Devices and accessories 3. "MODE" Button 5. Instrument panel - "MODE" button (Pin 2) - General ground (Pin 17) - +Key (Pin 19) - +Battery (Pin 20) 7.
  • Page 56 SCARABEO 125 - 200 Electrical system 24. Side stand switch pre-installation 27. Control unit 33. Battery 34. Main fuse 35. Auxiliary fuses 36. Plug socket 44. Thermal switch 45. Carburettor heater Lights and turn indicators 2. Light switch 5. Instrument panel...

  • Page 57: Checks And Inspections

    SCARABEO 125 - 200 Electrical system 16. Blinker 17. Arrow switch 19 Rear right arrow 20. Rear tail light/ stop light 21. License plate light 22 Rear left arrow 33. Battery 34. Main fuse 35. Auxiliary fuses 40. > Front position light 41 Front left arrow 42..
  • Page 58 SCARABEO 125 - 200 Electrical system RESET Hold the MODE button down. Turn the key to ''ON'' and wait 10 seconds. During this operation the service icon flashes at a 1 Hz frequency. ELE SYS - 58...

  • Page 59: Index Of Topics

    INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...

  • Page 60: Exhaust Silencer Removal

    SCARABEO 125 - 200 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, RE- PLACE THE CONNECTING INTERNAL GRAPHITE SLEEVE OF THE SILENCER TO THE EXHAUST PIPE.
  • Page 61 SCARABEO 125 - 200 Engine from vehicle • Remove the mudflap. • Remove the fuel tank. • Remove the rear wheel housing. • Empty the cooling system: • Release the radiator-head pipe «1» unscrewing the clamp «2» and the oil recovery pipe «3».
  • Page 62 SCARABEO 125 - 200 Engine from vehicle • Disconnect the cable of the carburettor starter from the connector «6». • Undo and remove the three screws «7» of the carburettor fitting. • Release the sas fitting operating on the clamp «8» and remove the entire sas.
  • Page 63 SCARABEO 125 - 200 Engine from vehicle • Disconnect the coolant temperature sensor cable «12». • Disconnect the connector «13» of the magneto flywheel cable and spark plug tube «14». NOTE GET A HOIST AND BELTS FOR LIFTING. • Fasten the belts to the chassis rear section.
  • Page 64 SCARABEO 125 - 200 Engine from vehicle • From the right side of the vehicle, un- screw and remove the engine fixing nut «16». Locking torques (N*m) M10 screw fixing connecting rod to engine (37 lbf ft) • From the opposite side slide off the pin «17».
  • Page 65 INDEX OF TOPICS NGINE...

  • Page 66: Automatic Transmission

    SCARABEO 125 - 200 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 67 SCARABEO 125 - 200 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 68 SCARABEO 125 - 200 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 69 SCARABEO 125 - 200 Engine Removing the driven pulley • Remove the transmission cover. • Remove the fixed driving half-pulley. • Lock the clutch bell with a calliper spanner. • Unscrew and remove the clutch nut. • Remove the clutch bell.
  • Page 70 SCARABEO 125 - 200 Engine Checking the bell working surface eccentricity - Fit the bell on a driven pulley shaft with 2 bearings (inside diameter: 15 and 17 mm). - Lock with the original spacer and nut. - Place the bell/shaft assembly on the support to check the crankshaft alignment.

  • Page 71: Removing The Clutch

    SCARABEO 125 - 200 Engine Removing the clutch Fit the special driven pulley spring compressor tool: • Fit the driven pulley assembly on the tool by inserting the three pins in the ventilation holes in the ground holder support. •...
  • Page 72 SCARABEO 125 - 200 Engine Removing the driven half-pulley bearing - Remove the retainer ring using two flat blade screwdrivers. - Using a hammer and pin, knock the ball bearing out as shown in the figure. - Remove the bearing and the rollers with the spe- cific extractor.
  • Page 73 SCARABEO 125 - 200 Engine Inspecting the driven sliding half-pulley - Remove the 2 inner sealing rings and the 2 O- rings. - Measure the inside diameter of the movable half- pulley bushing. Characteristic Minimum diameter allowed: Ø 41.08 mm Standard diameter Ø...
  • Page 74 SCARABEO 125 - 200 Engine Refitting the driven pulley - Check that the faying surfaces of the 2 half-pul- leys and the belt do not show any signs of wear, scoring or grease. - Insert the new oil seals and O-rings on the mov- able half-pulley.

  • Page 75: Specific Tooling

    SCARABEO 125 - 200 Engine Refitting the clutch - Assemble the spring, clutch and driven pulley. - Fit the clutch body on the appropriate tool with the adaptor - Insert the lever pin in the hole of the adaptor ring.

  • Page 76: Removing The Driving Pulley

    SCARABEO 125 - 200 Engine • Fit the clutch bell. • Lock the clutch bell. • Tighten the clutch nut. Locking torques (N*m) Rear CVT pulley fixing flanged nut - M12x1 (1) 60 Nm (44.25 lbf ft) - Loctite 243 Drive-belt •...
  • Page 77 SCARABEO 125 - 200 Engine • Remove the fixing nut and collect the washer. • Remove the fixed driving half-pulley. • Remove the spacer. 125 cm³ 1.5 mm 200 cm³ 1.8 mm • Detach the driving belt. • Remove the bushing.
  • Page 78 SCARABEO 125 - 200 Engine • 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. • Remove the spacer. Inspecting the rollers case •...
  • Page 79 SCARABEO 125 - 200 Engine • Check that the roller housings or the surfaces in contact with the belt on both half-pulleys are not worn. • Check that fixed driving pulley does not show signs of abnormal wear on the grooved edge and on the surface in contact with the belt.
  • Page 80 SCARABEO 125 - 200 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.
  • Page 81 SCARABEO 125 - 200 Engine • Fit the washer and tighten the nut. CAUTION CHECK THAT THE WASHER IS ADEQUATELY FITTED BE- FORE TIGHTENING THE NUT. NOTE REPLACE THE NUT WITH A NEW ONE AT EVERY REFIT. • Prevent fixed driving half-pulley rota- tion using the specific tool.
  • Page 82 SCARABEO 125 - 200 Engine Removing the hub cover • Drain the rear hub oil through the oil drainage plug located at the bottom of the crankcase. • Remove the eight flanged-head screws shown in the figure. • Remove the hub cover and the rele- vant gasket.
  • Page 83 SCARABEO 125 - 200 Engine • Remove the wheel axle with the gear. • Extract the driven pulley shaft from the bearing. See also Removing the hub cover Removing the hub bearings - Check the status of the bearings being examined (wear, clearance and noise).
  • Page 84 SCARABEO 125 - 200 Engine Removing the wheel axle bearings • Warm up the crankcase. • Remove the bearing using the specific extractor. Removing the driven pulley shaft bearing • Remove the driven pulley shaft. • Remove the oil seal using a screwdriv- er;...
  • Page 85 SCARABEO 125 - 200 Engine Refitting the driven pulley shaft bearing • Heat the parts with the specific heat gun. • Refit the bearing using the specific tool. Specific tooling 020702Y Main shaft bearing punch (15 x 42 x 13) on transmission cover •...
  • Page 86 SCARABEO 125 - 200 Engine Refitting the hub cover bearings • In order to fit the hub housing bearings, the parts must be heated with the spe- cific heat gun. • Fit the bearing in its position (1) on the cover of the hub housing on the driven pulley shaft, using the specific tool.

  • Page 87: Flywheel Cover

    SCARABEO 125 - 200 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 88: Removing The Stator

    SCARABEO 125 - 200 Engine Removing the hub cover • Detach the water pipe. • Undo and remove the eight screws. • 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.
  • Page 89 SCARABEO 125 - 200 Engine • Undo and remove the three screws fix- ing the stator and remove it together with the wiring. See also Removing the hub cover Refitting the stator • Install the stator following the removal steps but in reverse order.

  • Page 90: Removing The Starter Motor

    SCARABEO 125 - 200 Engine Refitting the flywheel cover • Place the oil pump shaft in the direction indicated by the reference arrow of the internal plate. • Place the water pump shaft with its grooves facing the reference point on the cover.
  • Page 91 SCARABEO 125 - 200 Engine • Unscrew and remove the two screws. • 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.

  • Page 92: Intermediate Gear

    SCARABEO 125 - 200 Engine • Extract the flywheel using the specific tool. Specific tooling 020707Y Flywheel extractor • Remove the cotter. Intermediate gear REMOVAL • Remove the flywheel, the cotter and the freewheel. • Slide off the intermediate gear.
  • Page 93 SCARABEO 125 - 200 Engine Removing the flywheel magneto FITTING • Fit the intermediate gear. Refitting the free wheel • Fit the cotter in its seat, be careful to position it as indicated in the photo- graph. • Fit the gear plus the pre-assembled...

  • Page 94: Removing The Rocker-Arms Cover

    SCARABEO 125 - 200 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...
  • Page 95 SCARABEO 125 - 200 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 96: Removing The Cam Shaft

    SCARABEO 125 - 200 Engine • Remove the chain tensioner bolt. • Remove the internal plate. • Remove the oil pump and the relevant chain. • Unscrew and remove the screw. • Remove the tensioner slider. • Remove the timing chain.

  • Page 97: Removing The Cylinder Head

    SCARABEO 125 - 200 Engine • Remove both camshafts. See also Removing the timing system drive Removing the cylinder head • Remove the camshafts. • Undo and remove the two side screws (1). • Loosen the screws (2- 3) operating di- agonally.

  • Page 98: Removing The Valves

    SCARABEO 125 - 200 Engine Removing the valves • Remove the head. • Place the head on supporting surface. • Number the valves and their bucket tappets in order to position them cor- rectly upon refitting. • Remove the valve bucket tappets.
  • Page 99 SCARABEO 125 - 200 Engine • Release the valve springs. • Remove the cap and the valve spring. • Remove the valves. - Remove the oil seals with a pair of pliers. See also Removing the cylinder head Removing the cylinder - piston assy.
  • Page 100 SCARABEO 125 - 200 Engine • Slide off the cylinder. • Remove the gasket between the cylin- der and the crankcase. CAUTION TO AVOID DAMAGING THE PISTON, KEEP IT FIRM WHILE REMOVING THE CYLINDER. • Remove the retainer rings from the pin.
  • Page 101 SCARABEO 125 - 200 Engine Maximum diameter: 15.023 mm (0.591 in) Standard diameter: 15.010 - 15.018 mm (0.5910 - 0.5912 in) 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)
  • Page 102 SCARABEO 125 - 200 Engine Piston pin hole - standard: 15.003 - 15.008 mm (0.5907 - 0.5908 in) 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)

  • Page 103: Sealing Rings

    SCARABEO 125 - 200 Engine NOME SIGLA CILINDRO PISTONE GIOCO AL MONTAGGIO Cilindro/Pistone 62,970 62,980 63,000 63,010 0,020 0,040 Cilindro/Pistone 62,980 62,990 63,010 63,020 0,020 0,040 ³ YLINDER PISTON COUPLING CLEARANCE Coupling categories with cast-iron cylinder NAME ABBREVIA CYLINDER PISTON...
  • Page 104 SCARABEO 125 - 200 Engine Choosing the gasket • Temporarily, fit the piston to the cylin- der, without base or head gasket. • Fit a dial gauge on the specific tool. • Zero set the dial gauge on the cylinder top surface and fit it on the two adja- cent stud bolts.

  • Page 105: Base Gasket Selection

    SCARABEO 125 - 200 Engine BASE GASKET SELECTION (125) Specification Desc./Quantity Size measured: (-0.15) - (-0.05) mm ((-0.0059) - (-0.0019) in) Gasket: 0.5 mm (0.019 in) Size measured: (-0.05) - 0.10 mm ((-0.0019) - 0.0039 in) Gasket: 0.4 mm (0.016 in) Size measured: 0.20 - 0.30 mm (0.0078 - 0.0118 in)

  • Page 106: Inspecting The Cylinder Head

    SCARABEO 125 - 200 Engine • Fit a new gasket between the cylinder and the head. • Place the two dowels. • Install the head. Inspecting the cylinder head • Using a trued bar, check that the head surface is not worn or distorted.
  • Page 107 SCARABEO 125 - 200 Engine Inspecting the valve sealings - Fit the valves into the cylinder head. - Alternatively test the intake and exhaust valves. - This test should be carried out by filling the mani- fold with petrol and checking that the head does not excessively ooze through the valves.
  • Page 108 SCARABEO 125 - 200 Engine • Replace the head if the values corre- sponding to the width of the mark on the valve seat or the valve guide diam- eter exceed the specified limits. • Check the width of the mark on the valve seat «V».
  • Page 109 SCARABEO 125 - 200 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 110 SCARABEO 125 - 200 Engine • Remove the chain tensioner. • Undo and remove the eight screws and remove the cam tower. • Remove the timing chain and the gears of the camshaft of the valves in ques- tion. •...
  • Page 111 SCARABEO 125 - 200 Engine • Fit the camshaft, the gears and the chain in their correct positions, using the references marked when these parts were removed. • Fit the cam tower and tighten the eight screws to the prescribed torque.

  • Page 112: Inspecting The Cam Shaft

    SCARABEO 125 - 200 Engine Specific tooling AP9100838 Tool for valve pressure plate AP8140179 Valve spring compressor Inspecting the cam shaft • Check the camshaft bearings for signs of abnormal wear. Characteristic Standard diameter - Bearing A 19.980 - 19.959 mm (0.7866 - 0.7858 in) Minimum diameter allowed - Bearing A 19.95 mm (0.7854 in)
  • Page 113 SCARABEO 125 - 200 Engine • Fit the chain guide slider onto the cyl- inder. • Fit the head gasket and the alignment dowels • Fit the head. • Screw but do not tighten both central long screws (3) and position the wash- ers.
  • Page 114 SCARABEO 125 - 200 Engine • Insert the camshafts in their seats on the head, remember to position the camshaft marked with the letter (A) on the intake side and the camshaft marked with the letter (S) on the ex- haust side.
  • Page 115 SCARABEO 125 - 200 Engine • Insert the chain tensioner bolt. • Place the chain tensioner spring. • Close the cap of the chain tensioner with a washer. Locking torques (N*m) Chain tensioner fixing screw - M18x10 (1) 35 Nm (25.81 lbf ft)

  • Page 116: Crankcase - Crankshaft

    SCARABEO 125 - 200 Engine • Refit the tappet cover. Specific tooling 0240880 Threaded bolt for locking crankshaft at TDC Locking torques (N*m) Transmission gear timing fixing screw - M8x20x1 (2) 27 Nm (19.91 lbf ft) - Loctite 243 Crankcase - crankshaft Splitting the crankcase halves •...

  • Page 117: Removing The Crankshaft

    SCARABEO 125 - 200 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 • Remove the main bushing oil seal.
  • Page 118 SCARABEO 125 - 200 Engine 020701Y Punch for bushings 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...
  • Page 119 SCARABEO 125 - 200 Engine Characteristic Maximum off-line allowed: A = 0.03 mm B = 0.03 mm Inspecting the crankcase halves • Before checking the crankcase halves, thoroughly clean all the surfaces and the oil pipes. • For the crankcase half on the transmission side, take particular care when handling the housing and hoses for the oil pump, the duct with the by-pass valve and the main bushings.
  • Page 120 SCARABEO 125 - 200 Engine YELLOW TYPE: 2.015 - 2.020 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...

  • Page 121: Oil Pressure Check

    SCARABEO 125 - 200 Engine • Place the two dowels and a new gasket between both crankcase halves. • Place the crankshaft half by giving short taps with a rubber hammer. • Tighten the three screws to the pre- scribed torque.

  • Page 122: Crankshaft Oil Seals

    SCARABEO 125 - 200 Engine - Check that the oil pressure reading is between 3.5 and 6.5 atm with engine idling at 6000 rpm and oil at the required temperature. - Remove the specific tools on the engine once the measurement is complete.

  • Page 123: Oil Pump

    SCARABEO 125 - 200 Engine Oil pump 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 124 SCARABEO 125 - 200 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 125 SCARABEO 125 - 200 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 126 SCARABEO 125 - 200 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...
  • Page 127 SCARABEO 125 - 200 Engine • Remove the 2 fixing screws shown in the figure, the vacuum chamber cover and the spring. • Remove the vacuum valve and the di- aphragm. WARNING WHILE REMOVING THE COVER, PAY ATTENTION NOT TO RELEASE THE SPRING ACCIDENTALLY.
  • Page 128 SCARABEO 125 - 200 Engine • Undo and remove the screw. • Remove the float and the pin. • Remove the maximum nozzle. • Remove the diffuser. • Remove the nozzle tilting the carburet- tor body. NOTE THIS OPERATION IS NECESSARY TO AVOID LOSING SPRAYER PARTS WHEN CLEANING THE CARBURETTOR BODY.
  • Page 129 SCARABEO 125 - 200 Engine • Remove the minimum nozzle. • Remove the minimum flow screw and collect the spring. CAUTION DO NOT TRY TO REMOVE PARTS EMBEDDED IN THE CARBURETTOR BODY SUCH AS: THE FUEL SUPPLY PIPE, THE PIN SEAT, THE STARTER JET, THROTTLE VALVE CONTROL SHAFT.
  • Page 130 SCARABEO 125 - 200 Engine • Replace the carburettor in case of irregularities. NOTE TO AVOID DAMAGES, DO NOT INTRODUCE METAL OBJECTS IN THE ADJUSTED SECTIONS. • Fit the spring and tighten the minimum flow screw. • Adjust the correct opening by opening...
  • Page 131 SCARABEO 125 - 200 Engine • Check that the tapered pin does not show signs of wear on the damped pin sealing surface and the return spring. • Replace the pin if it is worn. • Check that the float is not worn on the...
  • Page 132 SCARABEO 125 - 200 Engine • Once the new gasket of similar type has been fitted on the float chamber perimeter, place the chamber and tighten the three fixing screws. • Fit the vacuum valve and the dia- phragm. •...
  • Page 133 SCARABEO 125 - 200 Engine • Place the O-ring and the starter sup- port; tighten the screw. Level check - Make sure the float coupling plane is parallel to the float chamber plane with the carburettor in in- verted position.
  • Page 134 SCARABEO 125 - 200 Engine - Wash and blow the flow screw properly and fit a new O-Ring. - Preassemble the components on the screw as follows: spring, washer and O-Ring. - Screw the flow screw on the carburettor body.
  • Page 135 SCARABEO 125 - 200 Engine - Check that the diaphragm is not worn or has hardened. - Otherwise, replace it. - Refit the tapered pin on the vacuum valve. - Make sure the spring is correctly positioned on the pin and inserted in its fitting.

  • Page 136: Adjusting The Idle

    SCARABEO 125 - 200 Engine - The starter should be progressively disconnected by means of electrical heating. - Check the starter resistance when adjusted to the ambient temperature. Electric characteristic Keihin automatic starter resistance approximately 30 Ohm at 20°C - With a 12V battery power the automatic starter for 5 minutes and check that the piston goes out as much as possible.
  • Page 137 SCARABEO 125 - 200 Engine • an extension pipe, 25 cm (9.84 in) long minimum; • an rpm indicator. Specific tooling 020331Y Digital multimeter • Rest the vehicle on its centre stand. • Warm up the engine well until it rea- ches the temperature at which the electric fan switches on.
  • Page 138 SCARABEO 125 - 200 Engine • Operate on the air screw until a CO value of 3 ± 0.3 is obtained (approx. 2 turns from fully closed). • Open the secondary air passage and check that the CO value has dropped below 0.5% on the exhaust fumes an-...

  • Page 139: Index Of Topics

    INDEX OF TOPICS SUSP USPENSIONS...

  • Page 140: Removing The Front Wheel

    SCARABEO 125 - 200 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. Spacer 10.
  • Page 141 SCARABEO 125 - 200 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 142 SCARABEO 125 - 200 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 143: Wheel Axle

    SCARABEO 125 - 200 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 144: Front Fork

    SCARABEO 125 - 200 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 145 SCARABEO 125 - 200 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 146: Fork Removal

    SCARABEO 125 - 200 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 147 SCARABEO 125 - 200 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 148 SCARABEO 125 - 200 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 149 SCARABEO 125 - 200 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 150 SCARABEO 125 - 200 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 151 SCARABEO 125 - 200 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.

  • Page 152: Oil Filling

    SCARABEO 125 - 200 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 153: Steering Bearing

    SCARABEO 125 - 200 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 154: Removing The Rear Wheel

    SCARABEO 125 - 200 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 155 SCARABEO 125 - 200 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 156: Shock Absorbers

    SCARABEO 125 - 200 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 157 SCARABEO 125 - 200 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 158: Centre-Stand

    SCARABEO 125 - 200 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)

  • Page 159: Index Of Topics

    INDEX OF TOPICS BRAK SYS RAKING SYSTEM...

  • Page 160: Rear Brake Disc

    SCARABEO 125 - 200 Braking system Key: 1. Oil pipe screw 2. Front brake pipe 3. 10x14x1.6 Washer 4. M6x30 TE flanged screw 5. Valve 6. Pump-valve pipe 7. Front calliper-valve pipe 8. Rear calliper-valve pipe 9. Air bleed 10. Air bleed cap...

  • Page 161: Disc Inspection

    SCARABEO 125 - 200 Braking system Removal • Remove the rear wheel. • Undo and remove the five brake disc screws. • Remove the brake disc. CAUTION UPON REFITTING, APPLY THE RECOMMENDED PROD- UCT ON THE THREADING OF THE BRAKE DISC SCREWS.

  • Page 162: Front Brake Pads

    SCARABEO 125 - 200 Braking system Removal • Remove the front wheel. • Undo and remove the five brake disc screws. • Remove the brake disc. NOTE SCREW ALL THE SCREWS MANUALLY AND TIGHTEN THEM OPERATING DIAGONALLY CAUTION UPON REFITTING, APPLY THE RECOMMENDED PROD- UCT ON THE THREADING OF THE BRAKE DISC SCREWS.

  • Page 163: Rear Brake Pads

    SCARABEO 125 - 200 Braking system Removal • Remove the front brake calliper by un- screwing the two bolts «1». Locking torques (N*m) M8 screw fixing front brake calliper 25 (18.5 lbf ft) • Unscrew and remove the threaded cap «2».
  • Page 164 SCARABEO 125 - 200 Braking system Removal • Remove the rear brake calliper by un- screwing the two bolts «1». Locking torques (N*m) M8 screw fixing rear brake calliper 25 (18.5 lbf ft) • Remove the Seeger ring. • Slide off the pin.
  • Page 165 SCARABEO 125 - 200 Braking system • Slide off the brake pads. • Insert the two new brake pads. • Fit the spring. • Refit the pin. • Insert the Seeger ring. CAUTION AFTER REMOVING THE PADS, DO NOT OPERATE THE BRAKE CONTROL LEVER;...
  • Page 166 SCARABEO 125 - 200 Braking system • Quickly press and release the rear brake lever several times and then keep it fully pressed. • Loosen the bleed valve ¼ of a turn so that the brake fluid flows into the con- tainer.

  • Page 167: Rear Brake

    SCARABEO 125 - 200 Braking system BRAKE FLUID. CHECK THAT, DURING THE OPERATION, THERE IS ALWAYS BRAKE FLUID IN THE RESERVOIR. • Screw the bleeding valve and remove the pipe. • Top-up the reservoir until the correct brake fluid level is obtained.
  • Page 168 SCARABEO 125 - 200 Braking system CHECK THAT, DURING THE OPERATION, THERE IS AL- WAYS BRAKE FLUID IN THE RESERVOIR. OTHERWISE, IT WILL BE NECESSARY TO PURGE THE AIR AT THE END OF THE OPERATION. • Check that the fluid flows out of the...
  • Page 169 SCARABEO 125 - 200 Braking system Rear brake pump - combined Removal To remove the brakeforce distribution mechanism, proceed as follows: • Remove the shield back plate. • Drain off the braking system. NOTE MARK THE BRAKE PIPES TO PREVENT INCORRECT REFITTING.
  • Page 170 SCARABEO 125 - 200 Braking system See also Front side Rear - combined BRAK SYS - 170...
  • Page 171 INDEX OF TOPICS COOL SYS OOLING SYSTEM...

  • Page 172: Circuit Diagram

    SCARABEO 125 - 200 Cooling system Circuit diagram Key: 1. Expansion tank 2. Expansion tank cap 3. TBEI screw 4. M6 Clip 5. Breather pipe 6. Clamp 7. Radiator-exp. tank pipe 8. Breather pipe 9. Head-radiator pipe 10. Clamp 11. Pump-radiator pipe 12.
  • Page 173 SCARABEO 125 - 200 Cooling system Electric fan check Key: 7. Fan switch 8. Fan 9. Key switch 18. Engine stop switch 23. Ignition relay 24. Side stand switch pre-installation 33. Battery 34. Main fuse ELECTRIC FAN OPERATION CHECK To check the electric fan operation: •...
  • Page 174 SCARABEO 125 - 200 Cooling system • Undo and remove the screw «1» fixing the radiator. Locking torques (N*m) M6 fixing screw for radiator (on plastic) 6 (4.44 lbf ft) • Detach and lift the radiator to release it from its seat.

  • Page 175: Coolant Replacement

    SCARABEO 125 - 200 Cooling system F) / R OOLANT TEMPERATURE º º ESISTANCE VALUES Specification Desc./Quantity below 90º (194º) Infinite Above 90º (194º) Coolant replacement Emptying NOTE USE A CONTAINER OF ADEQUATE CAPACITY TO COLLECT THE FLUID THAT MAY LEAK DUR- ING OPERATION.

  • Page 176: Water Pump - Overhaul

    SCARABEO 125 - 200 Cooling system Water pump - overhaul WATER PUMP REMOVAL • Before removing the pump, empty the cooling system, drain off the engine oil and remove the flywheel crankcase. • Undo and remove the three screws and remove the water pump cover.
  • Page 177 SCARABEO 125 - 200 Cooling system COMPONENTS Check that the water pump housing cover, the water pump housing, the rotor and the seal are not damaged or excessively worn. Replace them if they are. Check that the intake and delivery pipes are not damaged or excessively worn.
  • Page 178 SCARABEO 125 - 200 Cooling system Top-up Level check Refitting the flywheel cover Thermostat Check Key: 5. Water temperature indicator in the instrument panel 9. Key switch 33. Battery 34. Main fuse 38. Water sensor Thermistor operation check • Remove the thermistor «2».
  • Page 179 SCARABEO 125 - 200 Cooling system • In the same container, immerse a ther- mometer «12» ranging from 0° + 150° C (32° + 302°F). • Place the container on a cooker «13» and heat the fluid slowly. • Check the temperature indicated in the thermometer and the value of the ther- mistor indicated in the tester.
  • Page 180 INDEX OF TOPICS CHAS HASSIS...
  • Page 181 SCARABEO 125 - 200 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 182: Instrument Panel

    SCARABEO 125 - 200 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 183 SCARABEO 125 - 200 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 184 SCARABEO 125 - 200 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-...
  • Page 185 SCARABEO 125 - 200 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. CAUTION PROCEED WITH CAUTION.
  • Page 186 SCARABEO 125 - 200 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 187: Side Fairings

    SCARABEO 125 - 200 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 188 SCARABEO 125 - 200 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 THE PLASTIC AND PAINTED COMPONENTS WITH CARE, DO NOT SCRATCH OR SPOIL THEM.
  • Page 189 SCARABEO 125 - 200 Chassis • Loosen the intake manifold clamp. • Remove the filter housing. Locking torques (N*m) Sleeve clamp on filter casing retainer 2 (1.48 lbf Tail guard • Park the vehicle on its centre stand. • Remove the rear luggage carrier.

  • Page 190: Rear Mudguard

    SCARABEO 125 - 200 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 191 SCARABEO 125 - 200 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 192 SCARABEO 125 - 200 Chassis • Release the saddle lock by undoing the two screws «5». • Disconnect the connector of the plug socket on the vehicle left side. • Remove the helmet compartment to- gether with the saddle by detaching it from the rubber protection.
  • Page 193 SCARABEO 125 - 200 Chassis Fuel tank Key: 1. Fuel tank 2. TBEI screw 3. M6 Clip 4. Fuel collection rubber ring 5. Fuel tank cap 6. Fuel level probe 7. M5 nut 8. Compl. coupling 9. Support 10. Fuel float chamber 11.
  • Page 194 SCARABEO 125 - 200 Chassis 21. Fuel pipe 22. Fuel pipe 23. Two-way joint 24. Fuel pipe 25. Diffuser pipe 26. Diffuser pipe 27. Pipe 28. Diffuser pipe To remove the fuel probe, proceed as follows: • Remove the rear luggage carrier.
  • Page 195 SCARABEO 125 - 200 Chassis • Empty the tank by removing the clamp «1» from the fuel pump. NOTE GET A COLLECTING CONTAINER BEFORE CARRYING OUT THESE OPERATIONS. • Detach the fuel pipe «2» from the fuel filter. • Detach the fuel pipe «3» from the fuel filter.

  • Page 196: Radiator Fan

    SCARABEO 125 - 200 Chassis • Unscrew and remove the two screws «5». Locking torques (N*m) M6 screw fixing fuel tank to chassis (on plas- tic) 6 (4.44 ftlb) • Remove the fuel tank. Radiator fan To remove the radiator, proceed as follows: •...

  • Page 197: Expansion Tank

    SCARABEO 125 - 200 Chassis • Detach and lift the radiator to release it from its seat • Disconnect the electric fan connector «3». Expansion tank • Empty the cooling system (SEE COOLANT CHANGE). • Remove the front shield. •...
  • Page 198 INDEX OF TOPICS PRE DE DELIVERY...
  • Page 199 SCARABEO 125 - 200 Pre-delivery Carry out the listed checks before delivering the vehicle. WARNING BE EXTREMELY CAUTIOUS WHEN HANDLING FUEL. Aesthetic inspection - Paintwork - Fitting of Plastic Parts - Scratches - Dirt Tightening torques inspection - Safety locks:...
  • Page 200 SCARABEO 125 - 200 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 201: Static Test

    SCARABEO 125 - 200 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)
  • Page 202 Accessories: 55 Air filter: 32, 188 Battery: 53 Brake: 160–163, 169 Carburettor: 126, 129 Clutch: 69–71, 74, 75 Coolant: 175 Engine oil: 33 Fork: 144 Fuel: 126, 193 Headlight: 40, 184 Hub oil: 30 Identification: 11 Instrument panel: 182 Maintenance: 8, 28 Mirrors: 181 Recommended products: Shock absorbers: 156...

This manual is also suitable for:

Scarabeo 200

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