Scarabeo 125-200ie Workshop PDF

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SERVICE STATION MANUAL

854291
SCARABEO 125 i.e. - 200 i.e.

SERVICE STATION
MANUAL
THE VALUE OF SERVICE

Due to the continuous technical updates and specific mechanic training programs for aprilia products,
only aprilia Official Network mechanics know this vehicle fully and have the special tools necessary to
carry out maintenance and repair operations correctly.
The reliability of the vehicle also depends on its mechanical state. Checking the vehicle before riding, its
regular maintenance and using only Original aprilia Spare Parts are essential!
For information about the nearest Official Dealer and/or Service Centre, consult the Yellow Pages or
search directly from the map on our Official Website:
www.aprilia.com
Only by requesting aprilia Original Spare Parts can you be sure of purchasing products that were
developed and tested together with the actual vehicle itself. All aprilia Original Spare Parts undergo
quality control procedures to guarantee reliability and durability.
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.
Not all versions/models shown in this publication are available in all Countries. The availability of
individual versions/models should be confirmed with the official aprilia sales network.
© Copyright 2009 aprilia. All rights reserved. Reproduction of this publication in whole or in part is
prohibited. aprilia - After-sales service.
Aprilia trademark is property of Piaggio & C. S.p.A.
SERVICE STATION MANUAL
- 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. Without this knowledge, repairing or
checking the vehicle may be inefficient or even dangerous. As the vehicle repair and check procedures
are not described in detail, be extremely cautious so as not to damage components or injure individuals.
In order to optimise customer satisfaction when using our vehicles, aprilia s.p.a. commits itself to
continually improve its products and the relative documentation. The main technical modifications and
changes in repair procedures are communicated to all aprilia Sales Outlets and its International
Subsidiaries. These changes will be introduced in the subsequent editions of the manual. In case of need
or further queries on repair and check procedures, consult aprilia CUSTOMER DEPARTMENT, which
will be prepared to provide any information on the subject and any further communications on updates
and technical changes related to the vehicle.
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.
Personal safety Failure to completely observe these instructions will result in serious risk of personal
injury.
Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicle
to prevent damaging the environment.
Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious
damage to the vehicle and sometimes even the invalidity of the guarantee.
INDEX OF TOPICS
CHARACTERISTICS CHAR
TOOLING TOOL
MAINTENANCE MAIN
ELECTRICAL SYSTEM ELE SYS
ENGINE FROM VEHICLE ENG VE
ENGINE ENG
INJECTION INJEC
SUSPENSIONS SUSP
BRAKING SYSTEM BRAK SYS
COOLING SYSTEM COOL SYS
CHASSIS CHAS
PRE-DELIVERY PRE DE
INDEX OF TOPICS
CHARACTERISTICS CHAR
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. WAIT UNTIL THE ENGINE AND THE EXHAUST SYSTEM ARE
COLD, IF POSSIBLE, RAISE THE VEHICLE USING A SUITABLE TOOL ON FIRM AND LEVEL
GROUND. TO AVOID BURNS PAY SPECIAL CARE WITH HOT ENGINE AND EXHAUST SYSTEM
PARTS.
DO NOT HOLD ANY MECHANICAL OR OTHER MOTORCYCLE PARTS WITH YOUR MOUTH:
MOTORCYCLE COMPONENT ARE NOT EDIBLE, ON THE CONTRARY SOME OF THEM ARE
HARMFUL AND EVEN TOXIC.
CARBON MONOXIDE
If you need to keep the engine running in order to carry out any procedure, please ensure that you do
so in an open or very well ventilated area.
Never let the engine run in an enclosed area.
If you do work in an enclosed area, make sure to use a smoke-extraction system.
CAUTION
EXHAUST EMISSIONS CONTAIN CARBON MONOXIDE, A POISONOUS GAS WHICH CAN CAUSE
LOSS OF CONSCIOUSNESS AND EVEN DEATH.
FUEL
CAUTION
FUEL USED TO DRIVE EXPLOSION ENGINES IS HIGHLY FLAMMABLE AND CAN BECOME EX-
PLOSIVE UNDER SPECIFIC CONDITIONS.
IT IS THEREFORE RECOMMENDED TO CARRY OUT REFUELLING AND MAINTENANCE PRO-
CEDURES IN A VENTILATED AREA WITH THE ENGINE SWITCHED OFF.
DO NOT SMOKE DURING REFUELLING AND NEAR FUEL VAPOURS, AVOIDING ANY CONTACT
WITH NAKED FLAMES, SPARKS OR OTHER SOURCES WHICH MAY CAUSE THEM TO IGNITE
OR EXPLODE.
CAUTION
DO NOT DISPOSE OF FUEL INTO THE ENVIRONMENT.

CAUTION
KEEP OUT OF THE REACH OF CHILDREN.

HIGH-TEMPERATURE COMPONENTS
CHAR - 7
Characteristics SCARABEO 125 i.e. - 200 i.e.
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.
TRANSMISSION OIL AND USED FORK OIL

CAUTION
IT IS ADVISABLE TO WEAR LATEX GLOVES WHEN CARRYING OUT SERVICE WORK.

THE TRANSMISSION OIL MAY CAUSE SKIN DAMAGE IF HANDLED FREQUENTLY AND FOR
LONG PERIODS.
WASH YOUR HANDS CAREFULLY AFTER HANDLING OIL.
HAND THE OIL OVER TO OR HAVE IT COLLECTED BY THE NEAREST USED OIL RECYCLING
COMPANY OR THE SUPPLIER.
IT IS ADVISABLE TO WEAR LATEX GLOVES WHEN CARRYING OUT SERVICE WORK.
CAUTION
DO NOT DISPOSE OF OIL INTO THE ENVIRONMENT.

CAUTION

BRAKE FLUID
CAUTION
THE BRAKE FLUID MAY DAMAGE PAINTED, PVC OR RUBBER SURFACES. WHEN SERVICING
THE BRAKE SYSTEM, PROTECT THESE COMPONENTS WITH A CLEAN CLOTH.
ALWAYS WEAR PROTECTIVE GOGGLES WHEN SERVICING THE BRAKE SYSTEM.
THE BRAKE FLUID IS EXTREMELY DANGEROUS TO THE EYES.
IN THE EVENT OF ACCIDENTAL CONTACT WITH THE EYES, RINSE THEM IMMEDIATELY WITH
ABUNDANT COLD, CLEAN WATER AND SEEK MEDICAL ADVICE.
CAUTION

HYDROGEN GAS AND BATTERY ELECTROLYTE
CAUTION
THE BATTERY ELECTROLYTE IS TOXIC, CORROSIVE AND AS IT CONTAINS SULPHURIC ACID,

IT CAN CAUSE BURNS WHEN IN CONTACT WITH THE SKIN.
WHEN HANDLING THE BATTERY ELECTROLYTE, WEAR TIGHT-FITTING GLOVES AND PRO-
TECTIVE APPAREL.
IF THE ELECTROLYTIC FLUID GETS INTO CONTACT WITH THE SKIN, WASH WITH ABUNDANT
COOL WATER.
IT IS PARTICULARLY IMPORTANT TO PROTECT THE EYES BECAUSE EVEN TINY AMOUNTS
OF BATTERY ACID MAY CAUSE BLINDNESS. IF IT COMES INTO CONTACT WITH THE EYES,
CHAR - 8
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-
LY.
THE BATTERY RELEASES EXPLOSIVE GASES. KEEP IT AWAY OF FLAMES, SPARKS, CIGA-
RETTES OR ANY OTHER HEAT SOURCE.
ENSURE ADEQUATE VENTILATION WHEN SERVICING OR RECHARGING THE BATTERY.
CAUTION

CAUTION
THE BATTERY LIQUID IS CORROSIVE.

DO NOT POUR OR SPILL IT, PARTICULARLY ON PLASTIC COMPONENTS.
ENSURE THAT THE ELECTROLYTIC ACID IS COMPATIBLE WITH THE BATTERY TO BE ACTI-
VATED.
Maintenance rules
GENERAL PRECAUTIONS AND INFORMATION

When repairing, dismantling and reassembling the vehicle, follow the recommendations given below
carefully.
CAUTION
UNLESS OTHERWISE INDICATED, REFIT THE UNIT FOLLOWING THE REMOVAL STEPS BUT
IN REVERSE ORDER. THE POSSIBLE OVERLAPPING OF OPERATIONS REFERRED TO IN THE
OTHER CHAPTERS MUST BE CARRIED OUT LOGICALLY, AVOIDING ANY UNNECESSARY RE-
MOVAL OF COMPONENTS. DO NOT POLISH MATT PAINTWORK WITH ABRASIVE PASTES.
NEVER USE FUEL AS SOLVENT FOR CLEANING THE MOTORCYCLE.
DO NOT USE ALCOHOL, PETROL OR SOLVENTS TO CLEAN RUBBER AND PLASTIC PARTS
AND THE SADDLE. USE ONLY WATER AND NEUTRAL SOAP INSTEAD.
DISCONNECT THE NEGATIVE CABLE (-) OF THE BATTERY IF YOU INTEND TO CARRY OUT
ELECTRICAL WELDING WORK.
BEFORE REMOVING COMPONENTS
• Before disassembling components, remove dirt, mud, dust and foreign bodies from the ve-
hicle.
• Use the special tools designed for this vehicle, as required.
COMPONENTS REMOVAL
• Do not loosen and/or tighten screws and nuts using pliers or any other tools than the specific
wrench.
• Mark the positions on all connection joints (pipes, cables, etc.) before separating them, and
identify them with different distinctive symbols.
• Each component needs to be clearly marked to enable identification during reassembly.
• Clean and wash the dismantled components carefully using a low-flammability detergent.
CHAR - 9
• Keep coupled parts together since they have "adjusted" to each other due to normal wear
and tear.
• Some components must be used together or replaced altogether.
• Keep away from heat sources.
REASSEMBLING COMPONENTS
CAUTION
NEVER REUSE A CIRCLIP; IF A CIRCLIP HAS BEEN REMOVED, IT MUST BE REPLACED WITH
A NEW ONE. WHEN INSTALLING A CIRCLIP, ENSURE THAT ITS ENDS ARE NOT STRETCHED
MORE THAN IS NECESSARY TO FIT IT ONTO THE SHAFT.
AFTER INSTALLING THE CIRCLIP, CHECK THAT IT IS FULLY AND CLEANLY INSTALLED IN ITS
SEAT.
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.
• When tightening nuts and screws, start either from the components with the largest diameter
or from the innermost components, proceeding diagonally. Tighten nuts and screws in suc-
cessive steps before applying the tightening torque.
• Always replace self-locking nuts, washers, sealing rings, circlips, O-rings (OR), cotter pins
and screws with new parts if the thread is damaged.
• When assembling the bearings, make sure to lubricate them well.
• Check that each component is assembled correctly.
• After a repair or routine maintenance, carry out pre-ride checks and test the vehicle on
private grounds or in an area with low traffic.
• Clean all mating surfaces, oil seal rims and gaskets before refitting. Smear a thin layer of
lithium-based grease on the oil seal rims. Reassemble the oil seal and the bearings with the
brand or lot number facing outward (visible side).
ELECTRIC CONNECTORS
Electric connectors must be disconnected as described below as non-compliance with the procedure
so described causes irreparable damage to both the connector and the cable harness: Press the rele-
vant safety hooks, if any.
CAUTION
DO NOT DISCONNECT CONNECTORS BY PULLING THE CABLES.

• Grip the two connectors and disconnect them by pulling them in opposite directions.
CHAR - 10
• 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.
• Then fit the two connectors making sure that they couple correctly (if the relevant hooks are
provided, you will hear them "click" into place).
TIGHTENING TORQUES
CAUTION
DO NOT FORGET THAT TIGHTENING TORQUES OF ALL FASTENING ELEMENTS ON WHEELS,

BRAKES, WHEEL AXLES AND OTHER SUSPENSION COMPONENTS PLAY A KEY ROLE IN EN-
SURING THE VEHICLE'S SAFETY AND MUST COMPLY WITH SPECIFIED VALUES.
CHECK THE TIGHTENING TORQUES OF FASTENING PARTS ON A REGULAR BASIS AND AL-
WAYS USE A TORQUE WRENCH TO REASSEMBLE THESE COMPONENTS.
IF THESE RECOMMENDATIONS ARE NOT COMPLIED WITH, ONE OF THE COMPONENTS MAY
BECOME LOOSE AND EVEN DETACHED, THUS BLOCKING A WHEEL, OR OTHERWISE COM-
PROMISING THE VEHICLE'S MANOEUVRABILITY. THIS CAN LEAD TO FALLS, WITH THE RISK
OF SERIOUS INJURY OR DEATH.
BRAKE FLUID
CAUTION
DO NOT USE FLUIDS OTHER THAN THOSE PRESCRIBED AND DO NOT MIX DIFFERENT LIQ-
UIDS WHEN TOPPING UP IN ORDER NOT TO DAMAGE THE BRAKE SYSTEM.
DO NOT USE BRAKE FLUID TAKEN FROM OLD CONTAINERS OR FROM CONTAINERS THAT
HAVE BEEN OPEN FOR A PROLONGED TIME.
SUDDEN CHANGES IN THE CLEARANCE OR ELASTIC RESISTANCE IN THE BRAKE LEVERS
ARE DUE TO FAULTS IN THE HYDRAULIC CIRCUIT.
MAKE ESPECIALLY SURE THAT BRAKE DISCS AND THE FRICTION MATERIAL ARE NOT
SMEARED OR GREASY, PARTICULARLY AFTER CARRYING OUT MAINTENANCE AND IN-
SPECTION OPERATIONS.
CHECK THAT BRAKE WIRES ARE NOT TWISTED OR WORN.
ENSURE THAT WATER OR DUST DO NOT INGRESS INADVERTENTLY INTO THE CIRCUIT.
IT IS ADVISABLE TO WEAR LATEX GLOVES WHEN SERVICING THE HYDRAULIC CIRCUIT.
DISC BRAKE
CAUTION
ANY OIL OR OTHER LIQUIDS ON A DISC WILL SOIL THE BRAKE PADS.
SOILED PADS MUST BE REMOVED AND REPLACED. A SOILED DISC OR A DISC WITH TRACES
OF OIL MUST BE CLEANED WITH A TOP QUALITY DEGREASING AGENT.
IF THE MOTORCYCLE IS USED CLOSE TO WATER OR ON DUSTY OR UNSURFACED ROADS,
OR IF IT IS USED FOR SPORTS APPLICATION, HALVE THE SERVICE INTERVALS.
COOLANT
Coolant liquid solution is 50% water and 50% antifreeze. This is the ideal mixture for most operating
temperatures and provides good corrosion protection.
This solution is also suited to the warm season, as it is less prone to evaporative loss and will reduce
the need for top-ups.
CHAR - 11
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.).
Use distilled water in the coolant mixture to avoid damaging the engine.
Depending on the freezing temperature of the coolant mixture you wish to achieve, add the percentage
of coolant indicated in the following table to the water:
FREEZING POINT C° (-°F)

Specification Desc./Quantity
-20° (-4) Coolant 35% by volume
NOTE
THE DIFFERENT ANTIFREEZE LIQUIDS HAVE DIFFERENT CHARACTERISTICS. THE DEGREE
OF PROTECTION GUARANTEED CAN BE FOUND ON THE LABEL OF THE PRODUCT.
CAUTION
USE ONLY ANTIFREEZE AND CORROSION INHIBITORS WITHOUT NITRITE THAT ENSURE A
PROTECTION OF AT LEAST -35°C (-31°F).
TYRES
CAUTION
CHANGING, REPAIR, MAINTENANCE AND BALANCING ARE IMPORTANT OPERATIONS THAT
ARE CARRIED OUT BY QUALIFIED PERSONNEL USING SUITABLE TOOLS.
THE NEW TYRES MAY BE COVERED WITH A THIN LAYER OF PROTECTIVE COATING THAT IS
SLIPPERY. DRIVE CAREFULLY FOR THE FIRST FEW KILOMETRES (MILES).
NEVER USE RUBBER TREATMENT AGENTS OF ANY KIND ON THE TYRES.
IN PARTICULAR ENSURE THAT THE TYRES DO NOT COME INTO CONTACT WITH LIQUID FUEL
THAT WOULD CAUSE A RAPID DETERIORATION OF THE RUBBER.
A TYRE THAT HAS BEEN IN CONTACT WITH OIL OR PETROL MUST BE REPLACED AND NOT
SIMPLY CLEANED.
DO NOT FIT TYRES WITH INNER TUBES ON WHEEL RIMS FOR TUBELESS TYRES AND VICE
VERSA.
Vehicle identification
These numbers are necessary for vehicle registration.

NOTE
ALTERING IDENTIFICATION NUMBERS CAN BE SERIOUSLY PUNISHED BY LAW, PARTICU-

LARLY MODIFYING THE CHASSIS NUMBER WILL IMMEDIATELY INVALIDATE THE WARRAN-
TY.
CHAR - 12
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.
Dimensions and mass
WEIGHT AND DIMENSIONS

Max. length 2040 mm
Max. width 720 mm
Max. height (to windshield) 1372 mm
Saddle height 810 mm
Wheelbase 1391 mm
Minimum ground clearance 145 mm
Weight in running order (kerb weight) 154 kg
Engine
ENGINE TECHNICAL DATA

Engine model BB01 (125)
CB01 (200)
Engine type Single-cylinder, 4-stroke, 4 valves, wet sump forced lubrication
system, double overhead camshaft.
Overall engine capacity 124.2 cm³ (125)
180.8 cm³ (200)
Bore/stroke 58 mm x 47 mm (125)
63 mm x 58 mm (200)
Compression ratio 12.0 ± 0.5 : 1 (125)
11.6 ± 0.5 : 1 (200)
Valve clearance Intake: 0.10 to 0.15
Exhaust: 0.20 - 0.25
Ignition starter
Idle speed 1900 ± 100 rpm (125)
1800 ± 100 rpm (200)
Clutch Automatic centrifugal dry clutch
CHAR - 13
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 NGK PMR9B
Transmission
TRANSMISSION
Transmission (125 - 200) CVT with belt + final reduction unit
CVT ratio (125) 2.9 : 1 - 0.89 : 1
CVT ratio (200) 2.4 : 1 - 0.86 : 1
Gear ratio (125) 14 / 66 x 23 / 58
Gear ratio (200) 14 / 66 x 27 / 54
Variator continuous, automatic
Primary drive V-belt
Secondary With gears
Engine/wheel total ratio (125) minimum: 34.5
maximum: 10.7
Engine/wheel total ratio (200) minimum: 22.5
maximum: 8.1
Variable speed rollers (125) - minimum diameter: 18.50 mm (0.73 in)
- standard diameter: 19.0 ± 0.1 mm (0.748 ± 0.004 in)
Variable speed rollers (200) - minimum diameter: 20.1 mm (0.79 in)
- standard diameter: 20.6 ± 0.1 mm (0.81 ± 0.004 in)
Pulley sliding bushing (125 - 200) - minimum diameter: 25.95 mm (1.022 in)
- standard diameter: 26.00 (-0.02/-0.041) mm (1.0236 (-0.0008/
+ 0.0016 in))
Movable pulley bushing (125 - 200) - maximum diameter: 26.121 mm (1.028 in)
- standard diameter: 26.000 (+0/0.121) mm (0.8661 (+0/+
0.0047 in))
Driving belt width (125 - 200) - minimum: 21.0 mm (0.827 in)
- standard: 22.0 +/- 0.2 mm (0.8661 +/- 0.0079 in)
Capacities
CAPACITY
Engine oil (Engine oil change and engine oil filter replacement) 1000 cm³
Transmission oil 200 cm³
Coolant 1.15 l (50% water + 50% ethylene glycol antifreeze fluid)
Depth of fork oil level from the rim - without spring - fork included 80 mm
Seats 2
Vehicle max. load (rider + passenger + luggage) 210 kg
Electrical system
ELECTRICAL SYSTEM
Battery 12V - 10 Ah
fuses 20 - 15 - 15 - 15 A
(Permanent-magnet) Alternator 12 V - 330W at 8000 rpm
CHAR - 14
BULBS/WARNING LIGHTS
1 High-/low-beam bulb 12 V 60/55 W H4
2 Tail light bulb 12V - 5W
3 Front and rear turn indicator bulbs 12V - 10 W (RY amber bulb)
4 License plate light bulb 12V - 5W
5 Rear daylight running light /stop light bulb 12V - 5/21W
6 Instrument panel lighting bulb (*) LED
7 Turn indicator warning light (*) LED
8 High-beam warning light (*) LED
9 Low fuel warning light (*) LED
10 Engine oil pressure warning light (*) LED
11 Electronic fuel injection check warning light (*) LED
(*) Cannot be replaced
Frame and suspensions
CHASSIS AND SUSPENSION

Size "A" 538.4 mm
Size "B" 439.3 mm
Steering rake angle 26.30°
Chassis type High-strength steel tubular chassis, single spar at the front, su-
perimposed double cradle at the rear.
Front suspension Hydraulic action telescopic fork
Front suspension travel 104 mm
Rear suspension hydraulic double-acting shock absorber and adjustable pre-
loading
Rear suspension travel 80 mm
Brakes
BRAKES
Front brake Ø 260 mm disc brake with hydraulic transmission
Rear brake Ø 220-mm disc brake with hydraulic transmission
Wheels and tyres
WHEELS AND TYRES

Wheel Rims made of light alloy
CHAR - 15
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 200 kPa (2.0 bar)
Front tyre standard inflation pressure with passenger 210 kPa (2.1 bar)
Rear tyre standard inflation pressure with passenger 220 kPa (2.2 bar)
Tightening Torques
FRONT BODYWORK UNIT

Name Torque in Nm
M6 screw fixing wheel housing to chassis and radiator support 6 (4.44 lbf ft)
M6 screw fixing front mudguard to fork 10 (7.4 lbf ft)
M5 screw fixing front mudguard to stem cover 4 (2.96 lbf ft)
M8 screw fixing of mudguard support to fork stems 25 (18.5 lbf ft)
Screw fixing bumpers to front shield fairings 1 (0.74 lbf ft)
Screw fixing chrome-plated moulding to internal shield 1 (0.74 lbf ft)
Screw fixing front shield fairings to shield fairing, lower section 2 (1.48 lbf ft)
Screw fixing wheel housing to front shield fairing 2 (1.48 lbf ft)
Screw fixing internal shield cover, internal section 1 (0.74 lbf ft)
Radiator grille to case fixing screw 1 (0.74 lbf ft)
Case to internal shield fixing screw 2 (1.48 lbf ft)
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)
Footrest to under-footrest fixing screw 1 (0.74 lbf ft)
Screw fixing under-footrest to rear lower side footrest 1 (0.74 lbf ft)
M5 screw fixing engine head access 4 (2.96 lbf ft)
Screw fixing engine head access, top side 1 (0.74 lbf ft)
Screw fixing side stand access to under-footrest 1 (0.74 lbf ft)
M6 screw fixing screw saddle lock to glove-box 5 (3.7 lbf ft)
M6 screw fixing glove-box to chassis 5 (3.7 lbf ft)
Screw fixing footrests to left and right tail fairing 1 (0.74 lbf ft)
Carburettor access fixing screw 1 (0.74 lbf ft)
Screw fixing right and left shield fairings to internal shield 2 (1.48 lbf ft)
Screw fixing glove-box lock to internal shield 1 (0.74 lbf ft)
M6 nut fixing saddle hinge to saddle 6 (4.44 lbf ft)
M5 screws fixing saddle hinge to saddle 4 (2.96 lbf ft)
Glove-box lid fixing screw 1 (0.74 lbf ft)
Screw fixing glove-box lid to internal shield 1 (0.74 lbf ft)
REAR BODYWORK UNIT

Name Torque in Nm
M6 screw fixing license plate holder to rear mudguard 5 (3.7 lbf ft)
Screw fixing tail fairing to helmet compartment, top and front 1 (0.74 lbf ft)
Taillight to tail fairing fixing screw 1 (0.74 lbf ft)
Rear passenger grab handle M8 fixing screw 25 (18.5 lbf ft)
Passenger grab handle cover fixing screw 1 (0.74 lbf ft)
M6 screw fixing rear mudguard to rear frame 5 (3.7 lbf ft)
M6 screw fixing rear mudguard to tail fairing 4 (2.96 lbf ft)
Screw fixing lower closure to Left and right side tail fairing 1 (0.74 lbf ft)
Screw fixing license plate light to rear mudguard 1 (0.74 lbf ft)
M5 screw fixing rear mudguard to silencer supporting plate 6 (4.44 lbf ft)
CHAR - 16
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)
tion, close to indicators
Instrument panel support fixing screw 1 (0.74 lbf ft)
Screw fixing instrument panel support to instrument panel 1 (0.74 lbf ft)
Screw fixing indicators cover to headlamp panel 1 (0.74 lbf ft)
Headlamp to headlamp panel fixing screw 1 (0.74 lbf ft)
Headlamp panel to handlebar fixing screw 1 (0.74 lbf ft)
M5 screw fixing left and right light switch 2 (1.48 lbf ft)
FRAME ASSEMBLY
Name Torque in Nm
M8 screw fixing curved support behind licence plate holder 25 (18.5 lbf ft)
HANDLEBAR UNIT
Name Torque in Nm
M10 screw fixing handlebar 52 (38.48 lbf ft)
M8 safety screw for handlebar 20 (14.8 lbf ft)
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)
M12 pin fixing single connecting rod to double connecting rod 60 (44.4 lbf ft)
STAND UNIT
Name Torque in Nm
M10 screw fixing stand to stand support 50 (37 lbf ft)
M8 screw fixing screw stand support to engine 25 (18.5 lbf ft)
BRAKING SYSTEM UNIT

Name Torque in Nm
M8 screw fixing front brake calliper 25 (18.5 lbf ft)
M8 screw fixing rear brake calliper 25 (18.5 lbf ft)
M6 screw fixing front brake pump to handlebar 10 (7.4 lbf ft)
Screw fixing the rear brake pump to the handlebar 10 (7.4 lbf ft)
M8 screws fixing front brake disc 25 (18.44 lbf ft) + Loctite 243
M8 screws fixing rear brake disc 25 (18.44 lbf ft) + Loctite 243
EXHAUST SYSTEM UNIT

Name Torque in Nm
M8 nut fixing nut exhaust manifold to engine 15 (11.1 lbf ft)
M10 screw fixing screw silencer clamp to exhaust manifold 17 (12.58 lbf ft)
M8 screw fixing silencer to plate 25 (18.5 lbf ft)
Lambda probe 50 (36.88 lbf ft)
COOLING SYSTEM UNIT

Name Torque in Nm
M6 fixing screw for radiator (on plastic) 6 (4.44 lbf ft)
Coolant piping clamp retainers 3 (2.22 lbf ft)
Screw fixing the electric fan to the radiator 1.5 (1.11 lbf ft)
M6 screw fixing expansion tank 4 (2.96 lbf ft)
CHAR - 17
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)
M6 fixing screw for voltage regulator 10 (7.4 lbf ft)
M6 fixing nut for start-up relay cables 6 (4.44 lbf ft)
M5 screws fixing fall sensor 4 (2.96 lbf ft)
M8 screw fixing fall sensor support 25 (18.5 lbf ft)
M6 screw fixing coil support 10 (7.4 lbf ft)
M3 screw fixing coil 2 (1.48 lbf ft)
FUEL TANK UNIT

Name Torque in Nm
M6 screw fixing tank to chassis 10 (7.4 lbf ft)
Ring nut fixing fuel pump 22 (16.23 lbf ft)
REAR SUSPENSION UNIT

Name Torque in Nm
M8 upper screw fixing shock absorber 25 (18.5 lbf ft)
M10 lower screw fixing shock absorber 50 (37 lbf ft)
M8 screw fixing shock absorber lower support to engine 25 (18.5 lbf ft)
REAR WHEEL UNIT

Name Torque in Nm
M14 fixing nut for rear wheel 110 (81.4 lbf ft)
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)
FRONT WHEEL UNIT

Name Torque in Nm
Wheel axle fixing screw 50 (37 lbf ft)
ENGINE UNIT
Name Torque in Nm
Intake manifold EI fixing screws - M6x20 (3) 10 Nm (7.38 lbf ft)
Oil filter cover EI fixing screws - M6x20 (2) 10 Nm (7.38 lbf ft)
Oil pump housing EI fixing screws - M6x25 (2) 10 Nm (7.38 lbf ft) - Loctite 243
Head fixing screw - M8x166 (4) 25 Nm + 90° (18.44 lbf ft + 90°)
Thermostat cover EI fixing screws - M6x20 (2) 10 Nm (7.38 lbf ft)
Head fixing screw (chain side) - M6x130 (2) 11 Nm (8.11 lbf ft)
Drainage fixing screw stud - M8x40 (2) 12 Nm (8.85 lbf ft)
Camshaft support EI fixing screws - M6x40 (8) 10 Nm (7.38 lbf ft)
Valve cover EI fixing screws - M6 (4) 10 Nm (7.38 lbf ft)
Chain tensioner retainer - M6x16 (2) 12 Nm (8.85 lbf ft)
Chain tensioner guide pad fulcrum fixing screws - M6 (1) 10 Nm (7.38 lbf ft) Loct. 243
Transmission gear timing fixing screw - M8x20x1 (2) 27 Nm (19.91 lbf ft) - Loctite 243
Transmission oil drainage plug - M12x1.5 (1) 25 Nm (18.44 lbf ft)
Right side crankcase oil drainage plug - M18x1.5 (1) 35 Nm (25.81 lbf ft)
Overpressure valve cap - M18x1.5 (1) 35 Nm (25.81 lbf ft)
Transmission oil filler cap - M14 x 1.5 -
Oil level cap - M16x1.5 (1) -
CHAR - 18
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 EI screws - M6x25 (1) 11 Nm (8.11 lbf ft)
Crankshaft timing hole cap EI screws - M8x14 (1) 15 Nm (11.06 lbf ft)
Oil pump plate EI screws - M5x12 (4) 6 Nm (4.42 lbf ft) - Loctite 243
Water pump housing EI fixing screws - M5x18 (3) 6 Nm (4.42 lbf ft)
Cover fixing screws CVT (125 cm³) - M6x35 (12) 10 Nm (7.38 lbf ft)
Cover fixing screws CVT (180 cm³) - M6x35 (11) 10 Nm (7.38 lbf ft)
Transmission cover EI fixing screws - M6x30 (8) 10 Nm (7.38 lbf ft)
Freewheel housing EI fixing screws - M8x20 (3) 25 Nm (18.44 lbf ft) - Loctite 243
Starter motor EI fixing screws - M6x25 (2) 10 Nm (7.38 lbf ft)
Stator EI fixing screws - M6x25 (3) 10 Nm (7.38 lbf ft) - Loctite 243
Rotor TEF fixing screw - M8x25 (1) 25 Nm (18.44 lbf ft) - Loctite 243
Rear CVT pulley fixing flanged nut - M12x1 (1) 60 Nm (44.25 lbf ft) - Loctite 243
Front CVT pulley fixing flanged nut - M12x1 (1) 75 Nm (55.32 lbf ft) - Loct. 243
Pick-up El fixing screws 6 Nm (4.42 lbf ft)
Stator cable bracket fixing screw - M5x8 (1) 4 Nm (2.95 lbf ft) - Loctite 243
Fuel injector fixing screw - M6x16 (1) 8 Nm (5.90 lbf ft)
Chain tensioning cover - M8 (1) 6 Nm (4.43 lbf ft)
Spark plug (1) 10 Nm (7.38 lbf ft)
Oil pressure switch TE screws - M10x1 (1) 10 Nm (7.38 lbf ft)
Thermistor fixing screws - M12x1.5 22 Nm (16.23 lbf ft)
Screw fixing the silencer plate to the engine 25 (18.5 lbf ft)
M6 screw fixing filter casing to engine 8 (5.92 lbf ft)
Sleeve clamp retainer in the throttle body 2 Nm (1.47 lbf ft)
Sleeve clamp on filter casing retainer 2 (1.48 lbf ft)
Water pump rotor 2 Nm (1.47 lbf ft)
Variator cover switch plate (125) 10 Nm (7.38 lbf ft)
Overhaul data
Assembly clearances
Cylinder - piston assy.
CYLINDER - PISTON COUPLING CLEARANCE 125 CM³

Coupling categories with cast-iron cylinder
NAME ABBREVIA CYLINDER PISTON FITTING

TION CLEARANCE
min max min max min max
Cylinder/Piston M 58,010 58,017 57,963 57,970 0,040 0,054
Cylinder/Piston N 58,017 58,024 57,970 57,977 0,040 0,054
Cylinder/Piston O 58,024 58,031 57,977 57,984 0,040 0,054
Cylinder/Piston P 58,031 58,038 57,984 57,991 0,040 0,054


TION CLEARANCE
CHAR - 19
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-
cation
AGIP BRAKE 4 Brake fluid FMVSS DOT4+
AGIP PERMANENT SPEZIAL Coolant Ready mixed biodegradable coolant with
"long life" technology and characteristics
(red). Freezing protection up to -40°C.
Compliant with CUNA 956-16 standard.
AGIP FILTER OIL Oil for air filter sponge -
NEUTRAL GREASE OR PETROLEUM BATTERY POLES -
JELLY
CHAR - 20
INDEX OF TOPICS
TOOLING TOOL
Tooling SCARABEO 125 i.e. - 200 i.e.
TOOLS
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
SCARABEO 125 i.e. - 200 i.e. Tooling

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

TDC
020704Y Extractor for bushings
TOOL - 23

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
TOOL - 24

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

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

AP0277512 Fitting buffer
AP8104517 Belt removal kit
AP8140196+AP8140578 Plurigas (AP8140196 in Italian,

AP8140578 in English)
020680Y TXB Navigator
TOOL - 27
INDEX OF TOPICS
MAINTENANCE MAIN
SCARABEO 125 i.e. - 200 i.e. Maintenance
Maintenance chart
ROUTINE 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 1 6 12 18 24 30 36 42 48 54 60
Driven pulley roller casing L L L L L
Safety fasteners I I I I I I
Plastic bushing in variator cover R R R R R
Clutch bell C C C C C C C C C C
Spark plug R R R R R
Driving belt R R R R R
Throttle control A A A A A A
Air filter C C C C C C C C C C
Transmission cover air duct filter I I I I I
Engine oil filter R R R R R R
Valve clearance A A A A A
Braking systems I I I I I I I I I I I
Electrical system and battery I I I I I I
Brake fluid ** I I I I I I
Coolant level** I I I I I I
Hub oil R I R I R I
Engine oil* R I R I R I R I R I R
Headlight aiming adjustment A A A A A
Sliding blocks / variable speed rollers R R R R R
Vehicle road test I I I I I I
Variator front movable half-pulley I I I I I
Radiator C C C
Wheels/tyres I I I I I I I I I I I
Suspension I I I I I
Steering I I I I I I
Transmission L L L L L
Fuel pipes *** I I I I I I
Spark plug
• Lift the saddle.

• Unscrew and remove the two screws
«3» (one at each side).
«4» (one at each side).
CAUTION
PROCEED WITH CAUTION.
DO NOT DAMAGE THE LOWER FIXING TABS AND/OR
THEIR CORRESPONDING SLOTS.
HANDLE THE PLASTIC AND PAINTED COMPONENTS
WITH CARE, DO NOT SCRATCH OR SPOIL THEM.
• Pull and slide off the front inspection cover «5».

NOTE
UPON REFITTING, INSERT THE FITTING TABS CORRECTLY IN THEIR SLOTS.
MAIN - 29
Maintenance SCARABEO 125 i.e. - 200 i.e.
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».
• Clean off any trace of dirt from the
spark plug base. Then unscrew it using
the spanner supplied in the toolkit and
remove it from its fitting, being careful
not to let dust or any other substance
come into the cylinder.
• Check that the spark plug electrode
and centre porcelain are free of carbon
deposits or signs of corrosion. If nec-
essary, clean using suitable spark plug
cleaners, a wire and/or metal brush.
• Blow with a strong air blast to avoid re-
moved dirt getting into the engine. Re-
place the spark plug if there are cracks
on the spark plug insulating material,
corroded electrodes or several depos-
its.
• Check the electrode gap with a feeler
gauge. This gap should be 0.7 - 0.8
mm; adjust it if necessary by carefully
bending the ground electrode.
• Make sure the washer is in good con-
ditions. Once the washer is fitted, man-
ually screw the spark plug to avoid
damaging the thread.
• Tighten using the spanner supplied in
the toolkit, make the spark plug com-
plete 1/2 of a turn to press the washer.
CAUTION
TIGHTEN THE SPARK PLUG CORRECTLY. OTHERWISE,
THE ENGINE MAY OVERHEAT AND GET IRRETRIEVABLE
DAMAGED.
MAIN - 30
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)
• Refit the spark plug tube «1» securely, so that it will not get detached when exposed to
engine vibrations.
• Refit the central inspection cover «5».
Hub oil
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.
Proceed as follows:
• Unscrew and remove the plug «1».

NOTE
GET A COLLECTING CONTAINER BEFORE CARRYING
OUT THESE OPERATIONS.
• Undo and remove the drain screw «2».
MAIN - 31
• 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
MOVING PARTS AND CAN CAUSE IRRETRIEVABLE DAMAGE.
Replacement
• Park the vehicle on firm and level ground.

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 (12.21 cu.in) capacity under the
drain screw «2».
• Undo and remove the drain screw.
• After having drained off the transmis-
sion oil, screw and tighten the drain
screw «2».
MAIN - 32
• 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.
Removal

• Unscrew and remove the seven
screws «1».
• 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.
Engine oil
Replacement
CAUTION
PARK THE MOTORCYCLE ON SAFE AND LEVEL GROUND.

CAUTION
MAIN - 33
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.
• Unscrew and pull out the measuring
cap-dipstick «1».
• 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» and slide off the engine oil
filter.
• Fit a new oil filter and the cover tight-
ening the two screws «3».
• Screw and tighten the engine oil drain-
age plug «4».
CAUTION
UPON REFITTING THE OIL FILTER COVER PAY ATTEN-
TION NOT TO DAMAGE THE O-RING.
• Pour approx. 950 cm³ (58 cu.in) engine oil through the fill opening «2».
• Screw and tighten the measuring cap-dipstick «1».
• Start the engine and let it run for several minutes. Stop the engine and let it cool down.
• Check engine oil level again.
Check
• Rest the vehicle on its centre stand.

CAUTION

CAUTION
THE ENGINE AND THE EXHAUST SYSTEM COMPONENTS CAN GET VERY HOT AND REMAIN
SO FOR SOME TIME EVEN AFTER THE ENGINE IS TURNED OFF. WEAR INSULATING GLOVES
BEFORE HANDLING THESE PARTS OR WAIT UNTIL THE ENGINE AND THE EXHAUST SYSTEM
COOL DOWN.
MAIN - 34
• 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.
• Unscrew and pull out the measuring
cap-dipstick «1».
• Clean the area in contact with oil with
a clean cloth.
• Place without screwing the cap-dip-
stick «1» into its tube «2».
• Remove the cap-dipstick «1» again
and read the level the oil reaches on
the dipstick.
• The level is correct when it is close to
the MAX level marked on the measur-
ing dipstick.
• Top-up if required.
TOP-UP
• Pour a small quantity of oil through the tube «2» and wait approximately five minutes so that
the oil flows evenly into the crankshaft.
• Check the oil level and top-up, if required.
• Top-up with small quantities of oil, until the recommended level is reached.
• At the end of the operation, screw and tighten the tap-dipstick «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
MOVING PARTS AND CAN CAUSE IRRETRIEVABLE DAMAGE.
MAIN - 35
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:

• Slide off the protection cover «1».
• Loosen the lock nut «2».
• Turn the set screw (3) so as to obtain
the specified value.
• After the adjustment, tighten the lock
nut (2) and check the empty travel
again.
• Refit the protection cover «1».
CAUTION
AFTER ADJUSTING, CHECK THAT MOVING THE HANDLE-

BAR DOES NOT MODIFY THE ENGINE IDLE SPEED AND
THAT ONCE RELEASED, THE THROTTLE GRIP HOMES
SMOOTHLY AND AUTOMATICALLY.
Cooling system
Level check
CAUTION
WAIT FOR THE ENGINE TO COOL DOWN BEFORE CHECKING OR TOPPING-UP THE COOLANT
LEVEL.
• Shut off the engine and wait until it cools off.
CAUTION
MAIN - 36
• 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:
• Remove the legshield.

CAUTION
WAIT FOR THE ENGINE TO COOL DOWN BEFORE CHECKING OR TOPPING-UP COOLANT
LEVEL.
• Loosen (turning it anticlockwise) but do
not remove the radiator cap «3».
• Wait for some seconds so that possible
pressure may be purged.
• Remove the radiator cap «3».
• Check that the there is coolant in the
radiator; top-up if required.
Top-up
CAUTION
WAIT FOR THE ENGINE TO COOL DOWN BEFORE CHECKING OR TOPPING-UP THE COOLANT
LEVEL.
• Remove the front shield.
• Remove the snap-on cover «1» from
the expansion tank «2».
CAUTION
DO NOT ADD ADDITIVES OR ANY OTHER SUBSTANCE TO

THE COOLANT.
• Top-up with coolant until the fluid level is near the ''MAX'' reference mark.
MAIN - 37
• 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.
RADIATOR LEVEL TOP-UP:
CAUTION
WAIT FOR THE ENGINE TO COOL DOWN BEFORE CHECKING OR TOPPING-UP COOLANT
LEVEL.
• Loosen (turning it anticlockwise) but do
not remove the radiator cap «3».
• Wait for some seconds so that possible
pressure may be purged.
• Remove the radiator cap «3».
• Top-up with coolant.
Braking system
CAUTION
CONSIDERING THE DANGER FOR VEHICLE AND RIDER, IT IS STRICTLY NECESSARY, AFTER
REFITTING BRAKES AND RESTORING THE BREAKING SYSTEM TO ITS REGULAR USE CON-
DITIONS, THAT THE HYDRAULIC CIRCUIT BE AIR PURGED.
NOTE
THIS VEHICLE IS FITTED WITH A BRAKING SYSTEM COMPRISING:
• A FRONT DISC BRAKE;
• A REAR DISC BRAKE.
Operating the right brake lever exerts pressure on the front brake calliper.
Operating the left brake lever exerts pressure on the front and rear brake callipers.
MAIN - 38
Level check

• 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».
• Check that the level in the reservoir is
over the reference «MIN» indicated on
the sight glass «1».
MIN = minimum level.

If the fluid does not reach at least the «MIN» ref-
erence mark:
CAUTION
BRAKE LEVEL DECREASES GRADUALLY AS BRAKE
PADS WEAR DOWN.
• Check brake pads and disc for wear. If the pads and/or the disc do not need replacing, top-up the
fluid.
Top-up
• Undo the four screws «4» to remove the brake pump cover «5».
CAUTION
RISK OF BRAKE FLUID SPILLS. DO NOT PULL THE FRONT BRAKE LEVER WHEN THE SCREWS
ARE LOOSE OR, MAINLY, WHEN THE BRAKE FLUID RESERVOIR COVER HAS BEEN RE-
MOVED. PLACE A CLOTH UNDER THE BRAKE FLUID RESERVOIR TO PROTECT IT FROM ANY
FLUID SPLASHES.
CAUTION
TOP-UP TO MAXIMUM LEVEL MARK ONLY WHEN BRAKE PADS ARE NEW. BRAKE FLUID LEV-
EL DECREASES GRADUALLY AS BRAKE PADS WEAR OUT.
WHEN TOPPING-UP, DO NOT EXCEED THE MAXIMUM LEVEL MARK WHEN BRAKE PADS ARE
WORN AS YOU RISK SPILLING FLUID WHEN CHANGING THE BRAKE PADS.
• Top-up.
MAIN - 39
System check
NOTE
THE FOLLOWING INFORMATION REFERS TO ONE BRAKING CIRCUIT BUT APPLIES TO BOTH.
To carry out a quick pad check:

• Visually check the brake disc and pads, as indicated below.
Front brake callipers

From the front bottom side for both pads.
Rear brake calliper

From the back bottom side for both pads «1».
• Replace both pads if the friction mate-

rial thickness (even in only one pad) is
reduced to about 1.5 mm.
Front pads "2".

Rear pads "3".
Headlight adjustment
EU - For a quick inspection of the correct aim-

ing of the front light beam:
• Place the vehicle 10 m (32.8 ft) from a

vertical wall and make sure the ground
is level.
• Turn on the low beam light, sit on the
vehicle and check that the light beam
projected to the wall is a little below the
headlight horizontal straight line (about
9/10 of the total height).
MAIN - 40
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.
MAIN - 41
INDEX OF TOPICS
ELECTRICAL SYSTEM ELE SYS

SCARABEO 125 i.e. - 200 i.e. Electrical system
Components arrangement
ELE SYS - 43
Electrical system SCARABEO 125 i.e. - 200 i.e.
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
- Front tail light: 12V - 5W
- High-/low-beam lights: 12V - 55W/12V - 60W H4
- Front turn indicator light: 12V - 10 W (RY amber
bulb)
4. Voltage regulator
- Recharging voltage: 13 - 15 V
- No-load voltage at terminals: 45 V
ELE SYS - 44
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. Engine H2O temperature sensor
COOLANT TEMPERATURE °C / RESISTANCE VALUE OHM

Characteristic Injection contact values Instrument panel contact values
50° 807 820
120° 105 80.6
8. Spark plug
Standard: NGK CR9EB
Alternatively: NGK PMR9B
ELE SYS - 45
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 (COLOUR - OHM) - CORRECT INDICATION

1 Grey/Green - Brown (14 Ohm) | [4/4 ± 5%]
2 Grey/Green - Brown (306 Ohm) | [0 ± 5%]
3 Grey/Green - Brown (176 Ohm) | [Warning light on]
11. Main fuses

- 20A fuse: direct positive (voltage regulator, in-
strument panel, ignition switch, plug socket fuse,
electric fan relay and ECU power supply).
- 15A fuse: plug socket power supply.
- 20A fuse: spare part.
ELE SYS - 46
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.
- 15A fuse: spare part.
14. Generator
- Permanent magnet: battery voltage 12 V - 300 W
at 6000 rpm.
- Rated power: 300 W
- Resistance value: 0.36 - 0.44 Ohm
- Resistance between the cables and the stator
support: endless
- Pick-up electric resistance: 129 +/-10% ohm
15. Turn indicators

12.8 V
2x10W+3.4W
ELE SYS - 47
16. Speed sensor
17. Fall sensor

- Horizontal position: 61.9 KOhm
- oblique position > 45°: 0 Hom
18. Control unit / throttle body
ELE SYS - 48
19. Injector
Electric resistance at ambient temperature: 14,5
Ohm
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. Front section
ELE SYS - 49
2. Rear section
Front side
A - Front headlamp
B - Handlebar
ELE SYS - 50
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.
4 - The fan connector must be placed behind the steering.
5 - Plastic clamp
ELE SYS - 51
ELE SYS - 52
ELE SYS - 53
D - Footrest
6 - Battery negative clamp.
7 - Diagnostic connector.
8 - Battery positive clamp
ELE SYS - 54
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
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.
4 - The cable harness must be aligned with the retainer.
5 - Plastic clamp
ELE SYS - 56
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.
11 - The ground lead must be fixed to the starter motor screw.
12 - Plastic clamp with locking system.
13 - The lambda probe connector must be fixed with a clamp to the engine.
14 - The cable harnesses of the starter motor and alternator must pass through the clamps.
ELE SYS - 57
ELE SYS - 58
ELE SYS - 59
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
ELE SYS - 61
Conceptual diagrams
KEY:
1. Multiple connectors
2. Fall sensor
3. ECU diagnosis
4. Electric fan
ELE SYS - 62
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
21.Start-up relay
22.STARTER MOTOR
23.Battery
24.Plug socket
25.Main fuses
26.Auxiliary fuses
27.Voltage regulator
28.Alternator
29.Pick-up
30.Engine oil pressure sensor
31.Injection relay
32.Lambda probe
33.Fuel pump unit
34.Ambient air temperature sensor
35.Fuel injector
36.Spark plug
37.Coil
38.Fan relay
39.Water Temperature Sensor
40.Injection ECU
41.Front right turn indicator
42.Headlamp
ELE SYS - 63
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
Gr Grey
M Brown
N Black
R Red
Ro Pink
V Green
Vi Purple
Checks and inspections
Dashboard
Km or miles selection
Pressing MODE button quickly, select the function of the battery voltage measurement. Hold down
MODE button for more than 10 seconds to shift from km to mile reading for the trip counter.
There will be no instrument panel indication for the first 5 seconds pressing the MODE button; for the
next 5 seconds the legend of the unit of measurement (km or miles) currently in use must flash at a
frequency of 1Hz. If the button is released before 10 seconds elapse, the unit of measurement does
not vary.
Data check function
SERVICE
ELE SYS - 64
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.
The warning light can be zero set even if the mileage is lower, up to 300 km (200 mi), compared with
the Service. During the 300 km (200 mi) before the service warning light lights up, the light flashes 5
times at each key ''ON''.
The light should turn on first at 1000 km (625 mi). Following times are strictly at 10000 km (6215 mi),
20000 km (12430 mi), etc.
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.
Connectors
ECU
KEY:
1. Injection warning light LED

2. -
3. -
4. Lambda probe "S"
5. Live
6. Battery supply
7. -
8. Electric fan relay
9. Water Temperature Sensor
10.-
11.Lambda probe "S+"
12.Engine stop
13.Engine speed sensor positive
ELE SYS - 65
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. Oil warning light

2. "MODE" button
3. Left turn indicator input
4. Right turn indicator input
5. High-beam light input
6. -
7. Sensors ground
8. Speed sensor ground
9. -
10.Speed sensor power supply
11.External temperature sensor input
12.Fuel level sensor input
13.Water temperature sensor input
14.Speed sensor input
15.-
16.Injector
17.General ground
18.-
19.+ Live
20.+ Battery
ELE SYS - 66
INDEX OF TOPICS
ENGINE FROM VEHICLE ENG VE

Engine from vehicle SCARABEO 125 i.e. - 200 i.e.
Exhaust assy. Removal
EXHAUST SILENCER REMOVAL

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.
• Loosen the clamp «1» fixing the ex-
haust silencer to the manifold.
• Undo and remove the three fixing
screws «2».
• Remove the exhaust silencer.

M10 screw fixing screw silencer clamp to ex-
haust manifold 17 (12.58 lbf ft) M8 screw fixing
silencer to plate 25 (18.5 lbf ft)
EXHAUST SYSTEM REMOVAL

• Remove the engine inspection cover.
• Disconnect the lambda probe connec-
tor.
CAUTION
ALLOW ENGINE AND EXHAUST SILENCER TO COOL OFF

COMPLETELY.
ENG VE - 68
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.

M8 screw fixing silencer to plate 25 (18.5 lbf ft)
Removal of the engine from the vehicle
Before removing the engine from the chassis, wash it and cut off coolant supply.
CAUTION
BEFORE CARRYING OUT THE OPERATIONS BELOW, BEAR IN MIND THAT THE ENGINE MUST
BE REMOVED FROM THE CHASSIS TOWARDS THE BOTTOM; AFTERWARDS ARRANGE AND
POSITION THE NECESSARY TOOLS.
CAUTION
MARK THE CABLES, SLEEVES, PIPES, ETC. TO AVOID INCORRECT REFITTING.
The procedure to remove the engine from the
chassis is described below sequentially:
• Remove the exhaust silencer.

• Remove the air filter box.
• Remove the helmet compartment.
• Remove the throttle body but keep it
connected to the throttle grip cables.
• Drain off the cooling system.
• Remove the rear brake calliper releas-
ing the cable grommet pipes on the
engine.
ENG VE - 69
• 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
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.
• Release the pipes and cable harnesses of any fastening clamp to the chassis.
• Fasten the belts to the chassis rear section.

• Lift the hoist arm until the belts are taut.
ENG VE - 71
• 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.
• Operating on the left side, slide off the

engine pin and collect the spacers.
• Slide off the chassis from the engine.
• The engine remains on the bearing
resting on the rear wheel and centre
stand.
• To refit the engine, carry out the removal steps but in reverse order.
ENG VE - 72
INDEX OF TOPICS
ENGINE ENG
Engine SCARABEO 125 i.e. - 200 i.e.
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.
• Remove the transmission cover.
• Remove the bushing from the support-

ing bearing of the driven pulley shaft on
the transmission cover by placing a
screwdriver in the slot on the transmis-
sion cover.
Air duct

(1).
• Undo and remove the three screws (2).
ENG - 74
SCARABEO 125 i.e. - 200 i.e. Engine
Air duct filter

• 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.
Removing the driven pulley shaft bearing

• Remove the bearing using the specific
extractor.
ENG - 75
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.
NOTE
ALWAYS REPLACE THE BEARING WITH A NEW ONE AT
EVERY REFIT
Specific tooling
020703Y Clutch shaft support bearing punch
(15x35x11) on crankcase cover
Removing the driven pulley

• Remove the fixed driving half-pulley.
• Lock the clutch bell with a calliper

spanner.
• Unscrew and remove the clutch nut.
• Remove the clutch bell.
ENG - 76
• 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.
- Measure the clutch bell inside diameter.
Characteristic
Clutch bell max. value
Max. value: Ø 135 mm
Clutch bell standard value
Standard value: Ø 134 to 134.2 mm
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.
- Using a dial gauge and the magnetic base, meas-

ure the bell eccentricity.
- Repeat the measurement at 3 positions (Central,
internal, external).
- In case of faults, replace the bell.
Specific tooling
alignment
020335Y Magnetic mounting for dial gauge
Characteristic
clutch bell check: Limit eccentricity.
ENG - 77
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
FROM ONE ANOTHER.
VARIOUS CONDITIONS CAN CAUSE THE CLUTCH TO
TEAR.
CAUTION
DO NOT OPEN THE MASSES USING TOOLS TO PREVENT
A VARIATION IN THE RETURN SPRING LOAD.
Characteristic
Check minimum thickness
1 mm
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.
• Make sure that the clutch is perfectly
inserted into the adapter ring before
proceeding to tighten the clutch nut.
• Use the special multipurpose wrench
to remove the nut fixing the clutch.
• Disassemble the driven pulley into its
components (Clutch and spring with
plastic fitting).
CAUTION
THE TOOL MUST BE FIRMLY FIXED IN THE VICE AND THE
CENTRAL SCREW MUST TOUCH THE TOOL. EXCESSIVE
TORQUE MAY DEFORM THE SPECIFIC TOOL.
Specific tooling
AP8140259 Universal tool for clutch assem-
blies
ENG - 78
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.
- 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.
NOTE
REST THE HALF-PULLEY ON A WOODEN SURFACE TO
AVOID DAMAGING ITS THREADED BUSHING. ALSO DO
THIS UPON REMOVAL.
Specific tooling
020375Y 28 x30 mm Punch
020439Y 17-mm guide for oil seal
ENG - 79
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.
- Measure the inside diameter of the movable half-
pulley bushing.
Characteristic
Minimum diameter allowed:
Ø 41.08 mm
Standard diameter
Ø 41.035 mm
Refitting the driven half-pulley bearing
- Fit the new roller bearing using the specific

punch, fit the bearing with the label facing outward
and insert it completely up to the punch stop on the
half-pulley.
NOTE
REST THE HALF-PULLEY ON A WOODEN SURFACE TO
AVOID DAMAGING ITS THREADED BUSHING. ALSO DO
THIS UPON REMOVAL.
Specific tooling
AP8140662 Punch for roller casing
ENG - 80
- 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
020439Y 17-mm guide for oil seal
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.
- Fit the half-pulley on the bushing with the appro-
priate protection sheath.
- Make sure the pins and collar are not worn, refit
the pins and the collar.
- Using a curved-spout grease gun, lubricate the
driven pulley unit with approximately 6 g of grease.
Apply the grease through one of the holes in the
bushing until grease comes out through the hole
on the opposite side. This procedure is necessary
to prevent the presence of grease beyond the O-
rings.
Specific tooling
AP8140664 Guide to mount the movable driven
pulley
Recommended products
AGIP GREASE SM2 Lithium grease with mo-
lybdenum for bearings and other points need-
ing lubrication
NLGI 2
ENG - 81
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.

- Fit the clutch body on the appropriate tool with
the adaptor
- Insert the lever pin in the hole of the adaptor ring.
- Tighten the fixing nut to the prescribed torque.
NOTE
WHEN PRELOADING THE SPRING, BE CAREFUL NOT TO
DAMAGE THE PLASTIC STOP OF THE SPRING AND THE
BUSHING THREADING.
NOTE
FOR DESIGN REASONS, THE NUT IS SLIGHTLY ASYM-
METRIC; THE FLATTEST SURFACE SHOULD BE MOUN-
TED CONTACTING THE CLUTCH.
Specific tooling
AP8140259 Universal tool for clutch assem-
blies
AP8140665 Adapter for clutch assembly re-
moval

Rear CVT pulley fixing flanged nut - M12x1 (1)
60 Nm (44.25 lbf ft) - Loctite 243
ENG - 82
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.
• Fit the clutch bell.

• Lock the clutch bell.
• Tighten the clutch nut.

Rear CVT pulley fixing flanged nut - M12x1 (1)
Drive-belt
• Make sure that the driving belt is not

damaged.
• Check belt for correct width.
Characteristic
Driving belt width (125 - 200)
- minimum: 21.0 mm (0.827 in)
- standard: 22.0 +/- 0.2 mm (0.8661 +/- 0.0079 in)
During the wear checks foreseen in the scheduled

maintenance services, check that the rim bottom
of the toothing does not show signs of incisions or
cracking (see figure): the rim bottom of the tooth
must not have incisions or cracking; if it does,
change the belt.
ENG - 83
Removing the driving pulley

• Unscrew the fixing nut with the specific
tool.
Specific tooling
• 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
ENG - 84
• 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.
• Remove the spacer.
ENG - 85
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.
• Check that the rollers are not damaged
or worn.
• Check that the guide sliders for the roll-
er contrast plate are not worn.
• 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.
CAUTION
DO NOT LUBRICATE OR CLEAN SINTERED BUSHINGS
Characteristic
Movable pulley bushing (125 - 200)
- maximum diameter: 26.121 mm (1.028 in)
- standard diameter: 26.000 (+0/0.121) mm (0.8661 (+0/+
0.0047 in))
Pulley sliding bushing (125 - 200)
- minimum diameter: 25.95 mm (1.022 in)
- standard diameter: 26.00 (-0.02/-0.041) mm (1.0236 (-0.0008/
+ 0.0016 in))
VARIABLE SPEED ROLLER
- minimum diameter (125): 18.50 mm (0.73 in)
- minimum diameter (200): 20.1 mm (0.79 in)
- standard diameter (125): 19.0 +/- 0.1 mm (0.748 +/- 0.004 in)
- standard diameter (200): 20.6 +/- 0.1 mm (0.811 +/- 0.004 in)
ENG - 86
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.
- Fit the entire bushing assembly on the crank-
shaft.
- Fit the driven pulley/Clutch/belt assembly to the
engine.
• Fit the driving belt.

• Install the spacer.
ENG - 87
• 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.
NOTE
REPLACE THE NUT WITH A NEW ONE AT EVERY REFIT
• Prevent fixed driving half-pulley rota-

tion using the specific tool. Tighten the
fixing nut to the prescribed torque.
Specific tooling

Front CVT pulley fixing flanged nut - M12x1
(1) 80 Nm (59 lbf ft) - Loctite 243
Refitting the transmission cover
• Fit the bushing to the shaft and add the

nut hexagon.
ENG - 88
• 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.

CVT cover EI fixing screws - M6x35 10 Nm (7.38
lbf ft)
End gear
Removing the hub cover
• Drain the rear hub oil through the oil

drainage plug located at the bottom of
the crankcase.
• Remove the eight screws shown in the
figure.
• Remove the hub cover and the rele-

vant gasket.
ENG - 89
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.
See also
ENG - 90
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.

extractor.
Removing the driven pulley shaft bearing
• Remove the driven pulley shaft.

• Remove the oil seal using a screwdriv-
er; working from inside the bearing and
being careful not to damage the hous-
ing, make it come out on the belt trans-
mission side.
extractor.
ENG - 91
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.

- Check the capacity of both the bearings and the wheel oil seal.
- In case of faults, replace the damaged parts.
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
• Fit a new oil seal on the transmission side of the belt, using the specific tool.
• Insert the driven pulley shaft.
Specific tooling
ENG - 92
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
020439Y Shaft 2 oil seal punch 17 mm
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.
Specific tooling
020702Y Main shaft bearing punch (15 x 42 x
13) on transmission cover
• Fit the bearing in its position (2) on the cover of the hub housing on the driven pulley shaft,
using the specific tool.
• Fit a new oil seal in the position (2), using the specific tool.
Specific tooling
ENG - 93
Refitting the hub bearings
- Assemble the 3 shafts in the engine crankcase

as shown in the figure.
ENG - 94
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.

Transmission cover EI fixing screws - M6x30
(8) 10 Nm (7.38 lbf ft)
Flywheel cover
• Detach the water pipe.

• Undo and remove the eight screws.
ENG - 95
• 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

• Undo and remove the two pick-up
screws.
• Undo and remove the three screws fix-

ing the stator and remove it together
with the wiring.
See also
ENG - 96
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.
• Refit the stator and the flywheel carry-

ing out the removal steps but in reverse
order; tighten the retainers to the speci-
fied torque.

Stator EI fixing screws - M6x25 (3) 10 Nm (7.38 lbf
ft) - Loctite 243
See also
Refitting the flywheel cover
• Place the oil pump shaft in the direction

indicated by the reference arrow of the
internal plate.
ENG - 97
• 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.

Ignition cover fixing screws - M6x110 (5) 11 Nm
(8.11 lbf ft) Ignition cover fixing screws - M6x140
(1) 11 Nm (8.11 lbf ft) Ignition cover fixing screws -
M6x170 (1) 11 Nm (8.11 lbf ft) Ignition cover EI
screws - M6x25 (1) 11 Nm (8.11 lbf ft)
Removing the starter motor
• Unscrew and remove the nut.

• Remove the power cable.
• Unscrew and remove the two screws.
ENG - 98
• Remove the starter motor by sliding it

off from one side.
Removing the flywheel magneto

• Lock the crankshaft with the specific
special tool.
Specific tooling
0240880 Threaded bolt for locking crankshaft
at TDC
• Undo and remove the screw.

• Collect the washer.
• Extract the flywheel using the specific

tool.
Specific tooling
020707Y Flywheel extractor
ENG - 99
• Remove the cotter.
Intermediate gear
FITTING
• Fit the intermediate gear.
REMOVAL
ENG - 100
• Remove the flywheel, the cotter and

the freewheel.
• Slide off the intermediate gear.
See also
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

freewheel, carefully check the coupling
with the crankshaft by means of the
cotter.
ENG - 101
Refitting the flywheel magneto
• Fit the flywheel paying attention to in-

sert the cotter adequately.
• Lock the flywheel nut to the prescribed
torque.

Rotor TEF fixing screw - M8x25 (1) 25 Nm (18.44
lbf ft) - Loctite 243
Refitting the starter motor
- If the O-ring is damaged, fit a new one on the

starter motor and lubricate it.
- Fit the starter motor on the crankcase and tighten
the 2 screws.
CAUTION
ADEQUATELY COUPLE THE MOTOR GEAR WITH THE
STARTER DOUBLE GEAR.

Starter motor EI fixing screws - M6x25 (2) 10 Nm
(7.38 lbf ft)
Cylinder assy. and timing system
Removing the rocker-arms cover
• Undo and remove the four screws.

• Remove the tappet cover.
ENG - 102
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.
Specific tooling
at TDC
• Get two Ø 6.3 mm (0.25 in) pins.
• Place the pins in their positions on the
overhead camshafts.
• Undo and remove the screw (1) and

collect the spring.
• Remove the screws (2) and take out
the chain tensioner with relevant gas-
ket.
• 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.
IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO EN-
SURE THAT THE DIRECTION OF ROTATION IS MAIN-
TAINED.
ENG - 103
See also
Removing the rocker-arms cover
Removing the cam shaft
• Remove the timing system control.

• Remove the chain tensioner.
• Undo and remove the eight screws.
• Remove the cam tower cap.
• Remove both camshafts.
See also
Removing the timing system drive
ENG - 104
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.
• Undo and remove both central long
screws (3) and collect the washers.
• Remove the head.

• Collect the lower chain slider.
See also
Removing the cam shaft
Removing the valves

• Place the head on supporting surface.
• Number the valves and their bucket
tappets in order to position them cor-
rectly upon refitting.
ENG - 105
• Remove the valve bucket tappets.
• Compress the valve spring using the

specific tool.
Specific tooling
• Remove both cotter pins.
• Release the valve springs.

• Remove the cap and the valve spring.
ENG - 106
• 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 water delivery sleeve.
• Remove the two dowels and the gasket
between the cylinder and the head.
• 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.
ENG - 107
• 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
• Measure the inside diameter of the

connecting rod small end using a spe-
cific micrometer.
NOTE
IF THE DIAMETER OF THE CONNECTING ROD SMALL
END EXCEEDS THE MAXIMUM DIAMETER ALLOWED,
SHOWS SIGNS OF WEAR OR OVERHEATING REPLACE
THE CRANKSHAFT AS DESCRIBED IN THE "CRANKCASE
AND CRANKSHAFT" CHAPTER".
Characteristic
Connecting rod small end (125 - 200)
Maximum diameter: 15.023 mm (0.591 in)
Standard diameter: 15.010 - 15.018 mm (0.5910 - 0.5912 in)
ENG - 108
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.
• Calculate the pin - piston coupling
clearance.
• Measure the piston outside diameter,
perpendicular to the pin axis.
• Take the measurement at 6 mm (0.24
in) from the base, at the position shown
in the figure.
• Carefully clean the sealing rings hous-
ings.
• Measure the sealing rings - grooves
coupling clearance using suitable sen-
sors, as shown in the diagram
• If clearances measured exceed the
limits specified in the table, the piston
should be replaced by a new one.
NOTE
MEASURE CLEARANCE BY INSERTING THE BLADE OF
THE FEELER GAUGE FROM THE 2nd SEALING RING
SIDE.
Characteristic
Piston / cylinder (125/200)
Piston pin hole - standard: 15.003 - 15.008 mm
(0.5907 - 0.5908 in)
ENG - 109
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)
- oil scraper: +0.01 / 0.19 mm (0.0004 / 0.007480 in)
Inspecting the cylinder
• Using a bore meter, measure the cyl-

inder inside diameter at three different
points according to the directions
shown in the figure.
• Check that the coupling surface with
the head is not worn or misshapen.
CAUTION
THE MARKING IS LOCATED ON THE PISTON CROWN.
Characteristic
Maximum run-out allowed:
0.05 mm


TION CLEARANCE


TION CLEARANCE
ENG - 110
Inspecting the piston rings
SEALING RINGS (125 / 200)

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 0.45 mm (0.18 in)
Middle ring maximum value 0.45 mm (0.18 in)
Removing the piston
- Install piston and pin onto the connecting rod, with the piston arrow aligned facing the exhaust.
- Fit the pin retainer ring on the appropriate tool.
Specific tooling
020705Y Piston seeger ring fitting
- With the opening in the position indicated on the

tool, set the retainer ring into position with the
punch.
- Fit the pin stop ring using the plug as shown in
the figure.
NOTE
THE TOOL FOR INSTALLING THE RETAINER RINGS MUST
BE USED MANUALLY.
CAUTION
USING A MALLET TO SET THE RINGS IN POSITION MAY
DAMAGE THE RING SEATS.
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.
• Remove the dial gauge and refit it on
the two stud bolts on the opposite an-
gles. Now measure again.
Specific tooling
AP8140266 Comparator door
ENG - 111
• 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
refitting. By correctly identifying the cyl-
inder base gasket thickness, an ade-
quate compression ratio can be main-
tained
• Remove the specific tool and the cyl-
inder.
Specific tooling
at TDC
Characteristic
Compression ratio (125)
12: 1
Compression ratio (200)
11.6: 1
BASE GASKET SELECTION (125)

Size measured: (1.05) - (1.20) mm ((0.041) - (0.047) in) Gasket: 0.3 mm (0.012 in)
Size measured: (1.20) - (140) mm ((0.047) - (0.055) in) Gasket: 0.4 mm (0.016 in)
Size measured: (1.40) - (1.55) mm ((0.055) - (0.061) in) Gasket: 0.5 mm (0.019 in)
BASE GASKET SELECTION (200)

Size measured: (-1.35) - (-1.20) mm ((-0.053) - (-0.047) in) Gasket: 0.3 mm (0.012 in)
ENG - 112
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. In any case, the tapered side of
the ring must be facing opposite the
piston crown.
• Fit the top piston ring with the identifi-
cation letter T facing the piston crown.
• Offset the piston ring gaps on the three
rings by 90º as shown in the figure.
• Lubricate the components with engine
oil.
Refitting the cylinder
• Fit a new cylinder base gasket of the

chosen thickness.
• Refit the cylinder as indicated in the
figure.
NOTE
BEFORE FITTING THE CYLINDER, CAREFULLY BLOW
AIR INTO THE LUBRICATION DUCT AND LUBRICATE THE
CYLINDER LINER.
• Fit a new gasket between the cylinder

and the head.
• Place the two dowels.
• Install the head.
ENG - 113
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.
Inspecting the timing system components
• Check that the guide slider and the ten-

sioner pad are not excessively worn.
• Check that the chain assembly, the
camshaft driving pulleys and the
sprocket wheel are not worn.
• Replace the parts if signs of wear are
found.
CHAIN TENSIONER
• Remove the central screw with the

washer and the tensioner spring.
Check that the one-way mechanism is
not worn.
• Check the condition of the tensioner
spring.
• If signs of wear are found, replace the
whole assembly.
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.
ENG - 114
- Measure the sealing surface width on the valve

seats.
VALVE SEALING SURFACE

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)
Valve chamfering (all valves) 0.2 +/- 0.1 mm x 45° (0.0079 +/- 0.0039 in x 45°)
Inspecting the valve housings
• Remove any carbon deposits from the valve guides.

• Measure the inside diameter of each valve guide.
• Measure according to the thrust direction at three different heights.
Characteristic
Intake guide - standard diameter
4.012 mm (0.1579 in)
Intake guide: Wear limit
4.020 mm (0.1582 in)
Discharge guide - standard diameter
4.012 mm (0.1579 in)
Discharge guide: Wear limit
4.020 mm (0.1582 in)
• 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».
Characteristic
Wear limit for the width of the mark on the valve
seat "V"
• Intake (125): 1.6 mm (0.0630 in)
• Exhaust (125): 1.8 mm (0.0708 in)
• Intake (200): 1.6 mm (0.0630 in)
• Exhaust (200): 2.0 mm (0.0787 in)
ENG - 115
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.
CAUTION
DO NOT CHANGE THE VALVE FITTING POSITION (RH - LH).
Characteristic
Minimum diameter allowed - Intake
3.96 mm (0.1559 in)
Minimum diameter allowed - Exhaust:
3.95 mm (0.1555 in)
Standard clearance - Intake:
0.015/0.042 mm (0.00059/ 0.0016 in)
Standard clearance - Exhaust:
0.025/0.052 mm (0.00098/ 0.00204 in)
Maximum clearance admitted - Intake:
0.060 mm (0.0023 in)
Maximum clearance admitted - Exhaust:
0.070 mm (0.0027 in)
ENG - 116
• 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.
Specific tooling
at TDC
• Use a feeler gauge to check clearance
on the four valves.
• If the values measured differ from the
values specified, record the difference
between MAXIMUM ALLOWED
CLEARANCE e CLEARANCE MEAS-
URED.
• 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.
ENG - 117
• 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.
• 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.
• Fit the chain tensioner.
• Use two Ø 6.3 mm (0.248 in) timing pins to check the camshafts are correctly timed.
• Check for correct valve clearance.
• Fit the head cover.
ENG - 118
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
• Lubricate the valve guides with engine

oil.
• Place the two oil seals on the head us-
ing a punch.
Specific tooling
AP0277512 Fitting buffer
- Fit the valves, the springs and the caps. Using the appropriate tool, compress the springs and fit the
cotters in their seats.
Specific tooling
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)
Intake cam height (125/200)
31.488 mm (1.23968 in)
Exhaust cam height (125/200)
ENG - 119
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.
Characteristic
Maximum axial clearance allowed:
0.4 mm (0.0157 in)
Refitting the head and timing system components
• Screw the specific tool so that the

crankshaft does not rotate at TDC.
Specific tooling
at TDC
• 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.
• Screw but do not tighten both central
long screws (2) and position the wash-
ers.
• Screw but do not tighten the two side
short screws (1).
NOTE
BEFORE INSTALLING THE HEAD, MAKE SURE THAT THE
LUBRICATION CHANNEL IS CLEAN AS WELL AS THE
REST OF THE ASSEMBLY; USE A JET OF COMPRESSED
AIR FOR CLEANING.
ENG - 120
• Tighten the four central screws (2 - 3) crosswise.

Head EI fixing screws - M8x166 (4) 25 Nm + 90° (18.44 lbf ft + 90°)
• Lastly, tighten the two side screws (1).

Head EI fixing screws (chain side) - M6x130 (2) 11 Nm (8.11 lbf ft)
• Insert the timing control chain on the
crankshaft.
• Insert the chain tensioner pad of the
head and lock it with the fixing screw.

Chain tensioner guide slider EI fixing screws -
M6 (1) 10 Nm (7.38 lbf ft) - Loctite 243
• 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.
WARNING
POSITION THE CAMS OF BOTH SHAFTS FACING OUT-
WARDS.
• Position the cam tower cap.

• Screw but do not and tighten the eight
screws.
ENG - 121
• 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.

Camshaft support EI fixing screws - M6x40 (8) 10 Nm (7.38 lbf ft)
• Place the camshaft gears on the chain,
be careful not to invert the original di-
rection of rotation.
• Keep the camshafts locked with the
pins and screw but do not tighten the
screws fixing the gears using Loctite
243.
• Fit the chain tensioner on the cylinder

using a new gasket, and tighten the two
screws (1) to the prescribed torque.
• Insert the spring with the central screw
(2) and o-ring, and tighten the cap to
the prescribed torque.

Chain tensioner retainer - M6x16 (2) 12 Nm (8.85
lbf ft) Chain tensioning cover - M8 (1) 6 Nm (4.43
lbf ft)
• Tighten the screws fixing the camshaft gears to the prescribed torque.
ENG - 122
• 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

Transmission gear timing fixing screw - M8x20x1 (2) 27 Nm (19.91 lbf ft) - Loctite 243
Crankcase - crankshaft
Splitting the crankcase halves
• Before opening the crankcase, drain out all engine oil, remove the driving pulley, the starter
motor, the flywheel, the freewheel and the intermediate gear.
• Remove the thermal group.
• Remove the oil pump.
• Unscrew and remove the three screws.
• Separate the crankcase halves by giv-

ing short taps with a rubber hammer.
CAUTION
PAY ATTENTION THAT THE TOOTHING OF BOTH THE
TIMING CHAIN GEARS AND THE OIL PUMP GEARS DO
NOT DAMAGE THE BUSHING.
ENG - 123
Removing the crankshaft
• Slide off the crankshaft from the fly-

wheel side by giving short taps with a
rubber hammer.
See also
Intermediate gear
Removing the crankshaft bearings
• Remove the main bushing oil seal.

• Using the suitable special tool, remove
the main bushings.
Specific tooling
020704Y Extractor for bushings
Refitting the crankshaft bearings
• Using the suitable tool, fit the new bushings on both crankcase halves.
Use bushings:
- blue
This coupling almost always meets the diametral clearance specifications
It should be checked that the diametral clearance is between 0.02 - 0.06 mm for both sides.
If this condition is not fulfilled, the bushing should be replaced with another of a different thickness.
These are the thickness for the half-bearings:
- red type: 2.005 - 2.010
- blue type: 2.010 - 2.015
yellow type: 2.015 - 2.020
Specific tooling
ENG - 124
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.
• In case of failure, replace the crank-
shaft.
• The crankshaft spare part has a sole
code (there are no different types to
select from).
• It should be checked that the diametral
clearance is between 0.02 mm
(0.00079 in) and 0.06 mm (0.0024 in)
for both sides.
• If this condition is not fulfilled, the half-
bearings should be replaced.
The big end bushings cannot be replaced.

Therefore, the connecting rod cannot be replaced
either. When cleaning the crankshaft, be very
careful that no impurities get in through the shaft
lubrication hole.
In order to prevent damaging the connecting rod
bushings, do not attempt cleaning the lubrication
duct with compressed air.
• The wrong installation of a buffer can

seriously affect the bushing lubrication
pressure.
NOTE
CRANKCASE BEARINGS ARE NOT GRINDABLE.
Specific tooling
alignment
Characteristic
Maximum off-line allowed:
ENG - 125
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.
• 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.
• As already described in the lubrication chapter, it is especially important that the by-pass
valve housing shows no wear that may impair the proper sealing of the lubrication pressure
adjustment ball.
• <DIV class=CNT_SUMMARY title="Testo Breve (<4000 car.)">Check that the surfaces are
free from dents or deformations, with special attention to both the crankcase coupling and
the cylinder-crankcase surfaces.
• <DIV class=CNT_SUMMARY title="Testo Breve (<4000 car.)">Defects in the crankcase
coupling gasket or the surfaces indicated in the figure can cause a drop in the oil pressure
and affect the lubrication pressure for the main bushings and the connecting rod.
• <DIV class=CNT_SUMMARY title="Testo Breve (<4000 car.)">Check that the surfaces that
limit crankshaft axial clearance show no signs of wear. To measure and check sizes follow
the procedure described previously for checking crankshaft axial clearance and dimensions.
Inspecting the crankshaft plain bearings

• In order to correctly lubricate the bushings, it is necessary to have both optimal lubricating
pressure and a good oil flow rate; this implies that the bushings must be positioned correctly
so as not to obstruct the oil supply ducts.
• The main bushings comprise two half-bearings. The two half-bearings for the left crankcase
bushing (variator side) are plain with holes. The two half-bearings for the right crankcase
bushing (flywheel side) have holes and a central groove.
• The oil supplying channel section is also influenced by the depth to which the bushings are
driven compared with the crankshaft axial clearance of the limiting surface.
CAUTION
THE MAIN BUSHINGS SHOULD BE FITTED WITH THE COUPLING AREA FOR BOTH HALF-
BUSHINGS PARALLEL TO THE CYLINDER SUPPORTING SURFACE AND WITH THE HOLES OF
THE LUBRICATION GROOVE PERFECTLY CENTRED.
• Measure the bushings diameter at the 3 positions indicated in the figure.
• Bushings are divided into 3 categories according to their thickness.
RED TYPE: 2.005 - 2.010
BLUE TYPE: 2.010 - 2.015
YELLOW TYPE: 2.015 - 2.020
ENG - 126
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
• Using the suitable special tool, fit the

main bushings.
• Fit the new oil seal using a commer-
cially available punch.
Specific tooling
• Fit the crankshaft operating from the

variator side.
Refitting the crankcase halves
• Fit the crankshaft.
• Place the two dowels and a new gasket

between both crankcase halves.
ENG - 127
• 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.

Crankcase EI fixing screws - M6x70 (1) 11 Nm
(8.11 lbf ft) Crankcase EI fixing screws - M6x50
(2) 11 Nm (8.11 lbf ft)
See also
Refitting the
crankshaft
Oil pressure check
- Disconnect the electrical connection of the mini-

mum oil pressure switch and then remove the
switch.
- Check that the oil pressure reading is 1.8 atm
minimum with engine idling at 1700 +/- 100 rpm
and oil at the required temperature (wait for at least
one electric ventilation).
- 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. Refit the oil pressure
switch and washer, tightening it to the prescribed
torque, and fit the flywheel cover.
- If oil pressure reading are not within the specified
limits, check in the following order: the oil filter, the
ENG - 128
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.
Crankshaft oil seals
Removal
• Remove the crankshaft.

• Remove the main bushing oil seal
working from the transmission side.
CAUTION
BE CAREFUL NOT TO DAMAGE THE SEAT OF THE MAIN
BUSHING OIL SEAL.
Refitting
• Thoroughly clean the seat of the oil seal.

• Fit the new main bushing oil seal using a commercially available punch of suitable size.
CAUTION
PREPARE THE NEW OIL SEAL BY LUBRICATING ITS SEALING LIP. DO NOT LUBRICATE THE
KEYING SURFACE ON THE ENGINE CRANKCASE
Oil pump
ENG - 129
Removal
• Drain the engine oil.

• Remove the flywheel.
• Undo and remove the four screws and
remove the plate.
• Unscrew and remove the two screws.

• Slide off the gears, the oil pump and
the chain.
IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO EN-
SURE THAT THE DIRECTION OF ROTATION IS MAIN-
TAINED.
See also
Inspection
• Remove the oil pump.

• Remove the seeger ring and slide off
the gears from the oil pump.
ENG - 130
• 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.
- Measure distance between rotors with a feeler

gauge at the position shown in the picture.
Characteristic
Limit clearance allowed:
0.12 mm
ENG - 131
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
See also
Removal
Refitting
• Preassemble the entire oil unit, the

chain (observing the direction of rota-
tion marked when fitting) and the
crankshaft driving gear.
• Insert the oil pump spindle in its posi-
tion and fit the oil pump in its housing.
• Tighten the two screws with Loctite
243.

Oil pump housing EI fixing screws - M6x25 (2)
ENG - 132
• 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.

Oil pump plate EI screws - M5x12 (4) 6 Nm (4.42
lbf ft) - Loctite 243
ENG - 133
INDEX OF TOPICS
INJECTION INJEC
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.
Carburetion and ignition are managed on the basis of the engine revs and throttle valve opening. Further
corrections are made according to the following parameters:
- Coolant temperature
- Intake air temperature
- Lambda probe value
The system implements an idle supply correction with cold engine through a Stepper motor on a by-
pass circuit of the throttle valve. The electronic control unit manages the Stepper motor and the injector
opening time, thereby ensuring idle steadiness and proper carburetion.
In all conditions of use, carburetion is controlled by modifying the injector opening time.
Fuel delivery pressure is kept constant based on the ambient pressure.
The fuel supply circuit consists of:
- Fuel pump
- Fuel filter
- Injector
- Pressure regulator
Pump, filter and regulator are placed into the fuel tank using a single support.
The injector is connected by two pipes provided with fast-release fittings. This results in a continuous
circulation, thereby avoiding the risk of fuel boiling. The pressure regulator is at the end of the circuit.
The fuel pump is controlled by the MIU control unit; therefore the vehicle's safety is enhanced.
The ignition circuit consists of:
- HV coil
- HV cable
- Shielded cap
- MIU control unit
- Spark plug
The MIU control unit manages the ignition with the best advance ensuring 4-stroke timing (ignition only
in the compression stroke) at the same time.
The MIU injection-ignition system controls engine functions by means of a pre-set program.
Should any input signals fail, an acceptable working order of the engine is ensured to allow the user to
reach a service station.
Obviously, this cannot happen when the rev counter signal is missing, or when the failure concerns the
control circuits:
- Fuel pump
INJEC - 135
Injection SCARABEO 125 i.e. - 200 i.e.
- 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).
The diagnostic tester is also required for adjusting
idle speed carburetion.
Specific tooling
AP8140595 Axone + battery charger (230V
50Hz)
60Hz)
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).
The diagnostic tester is also required for adjusting
idle speed carburetion.
Specific tooling
50Hz)
60Hz)
The MIU control unit power supply is further controlled by the emergency switch to further enhance
vehicle safety.
Precautions
Troubleshooting tips
1 A failure of the MIU system is more likely to be due to the connections rather than the components.
Before searching the MIU system for failures, check:
A: Power supply
INJEC - 136
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. Broken shielded cap
E: Intake circuit
a. Dirty air filter
b. Clogged by-pass circuit
c. Faulty stepper motor
F: Others
a. Not correctly adjusted timing system
b. Not correct idle carburetion
c. Not correctly reset throttle valve position sensor
2 MIU system failure may be caused by loose connectors. Make sure that all connections are properly
implemented.
Check the connectors as follows:
A check that the terminals are not bent.
B check that the connectors have been properly connected.
C see whether the malfunction can be fixed by slightly shaking the connector.
3 Check the entire system carefully before replacing the MIU control unit. If the fault is still present after
the MIU control unit is replaced, install the original control unit again and check whether the fault occurs
again.
4 Use a multimeter with an internal resistance over 10 K W /V when troubleshooting. Instruments that
are not suitable may damage the MIU control unit. Instruments must be used with definitions over 0.1
V and 0.5 W , the precision must be greater than 2%.
INJEC - 137
Hand-held computer menu
PALMTOP COMPUTER MENU SYMBOLS

1. ISO
2. Engine parameter reading
3. Device status (in general, values are ON - OFF)
4. Devices activation
5. Errors display
6. Adjustable parameters/Fixed parameters
ISO
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
(see the note related to the mapping parameter)
Aprilia software Not relevant field
Service number (XX)
ENGINE Engine capacity
Produced (dd/mm/yy) Electronic control unit production date
Mapping (XXXXXX) Indicates the code of the configuration present on the control
unit
Programming date (dd/mm/yy) Date of last mapping downloading: day/month/year
Person in charge of last programming (XXXXX) Identification code of the PC or Axone that has loaded the last
mapping. In this 5.0.2 version, the code displayed is not right:
in order to view it correctly, go to the ISO screen page that is
displayed when selecting RESETTING
ENGINE PARAMETER READING

Water temperature (°C) Detected by the sensor placed on the engine
Air temperature (°C) Temperature measured when entering the engine (sensor in
the throttle body). Caution! the instrument panel temperature
is read by a different sensor
Engine revs (rpm) Measured by the crankshaft rpm detection sensor
Target idle revs (1600 rpm) Target revs saved to the electronic control unit memory (they
vary according to engine temperature)
Ignition advance Ignition advance in relation to TDC
TPS Trimmer
Idle motor (50 steps) Idle motor position, example value measured with warm engine
Battery voltage (V) Voltage measured at battery leads
Number of engine strokes in which more than a tooth have Shows 1 if it detects that more than one tooth is missing in the
been lost since the beginning of the trip (0/1) sprocket
Number of engine strokes in which one single tooth has been Shows 1 if it detects that one tooth is missing in the sprocket
lost since the beginning of the trip (0/1)
Difference between actual and target steps (steps) Difference between target steps and actual steps of the idle
motor
Lambda sensor correction (1) Value that must be close to 1 when the control unit is using the
lambda probe signal to keep the stoichiometric combustion
Lambda probe (100-900 mV) Lambda probe signal voltage, fixed value if the circuit is inter-
rupted
Injection time (ms) Injector activation time
Atmospheric pressure (760 mmHg) Air atmospheric pressure (for mapping adjustment)
Partial load self-adjustment (mg/cc) Parameter for lambda probe self-adjustment for partial loads
Value adaptability at idle (mg/cc) Parameter for lambda probe self-adjustment at idle speed
Gain value adaptability (%) Parameter for lambda probe self-adjustment at full load
INJEC - 138
DEVICE STATUS
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) ON if the control unit is using the lambda probe signal to keep
the stoichiometric combustion
ADJUSTABLE PARAMETERS
Throttle position self-acquisition Just press the ENTER button to save the throttle closed posi-
tion
Self-adjustable parameters reset Lambda probe self-adaptability parameters reset (if a new en-
gine, a new lambda probe or a new injector is installed)
DEVICES ACTIVATION
Error clearing Press "enter" to transfer errors from the memory (MEM) to the
historical record (STO). The next time Axone is connected to
the ECU, the errors in the historical record (STO) will no longer
be displayed
Fuel pump The device is activated: if it is not correctly activated, this will
be immediately shown in the Axone screen page
Coil The device is activated: if it is not correctly activated, this will
Injectors The device is activated: if it is not correctly activated, this will
Electric fan The device is activated: if it is not correctly activated, this will
Idle motor The device is activated: if it is not correctly activated, this will
ERRORS DISPLAY
Throttle If the throttle position sensor signal is interrupted
Pressure If the atmospheric pressure sensor signal is interrupted
Lambda probe Displayed if the probe signal circuit is interrupted
Water temperature Sensor, circuit or relevant connectors interrupted
Air temperature (°C) Sensor, circuit or relevant connectors interrupted
Battery voltage
Injector Sensor, circuit or relevant connectors interrupted
Coil Sensor, circuit or relevant connectors interrupted
Idle motor Sensor, circuit or relevant connectors interrupted
Fuel pump relay
Electric fan Sensor, circuit or relevant connectors interrupted
Self-adjustable parameters
RAM memory Control unit internal error
ROM memory Control unit internal error
EEPROM Control unit internal error
Microprocessor Control unit internal error
Rpm sensor If the crankshaft rpm detection sensor is disconnected, this er-
ror is not shown
INJEC - 139
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.
• Select the function: "throttle position self-acquis-
ition".
• Make sure the left throttle is fully in.
• Press the "ENTER" key.
• Turn the key to "OFF" and leave it for at least 30
seconds.
Troubleshooting procedure
Engine does not start
ENGINE DOES NOT START EVEN IF PULLED

Possible Cause Operation
Faults detected by self-diagnosis Pump relay
HV coil
Injector
Engine speed timing sensor
Fuel system Fuel present in the tank
Fuel pump activation
Fuel pressure (low)
Injector flow (low)
Power to the spark plug Spark plug Shielded cap HV Coil (secondary insulation)
Parameter reliability Coolant temperature
Distribution timing adjustment - injection start
Intake air temperature
Starting difficulties
ENGINE START-UP PROBLEMS

HV coil
Injector
Air temperature
Coolant temperature
Start-up speed Starter motor and solenoid
BATTERY
Ground connections
Power to the spark plug Spark plug
Shielded cap
HV coil
Ignition advance
Fuel system Fuel pressure (low)
Injector flow (low)
Injector seal (poor)
INJEC - 140

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
HV coil
Injector
Air temperature
Coolant temperature
Ignition efficiency Spark plug
Ignition timing
Correctness of the parameters Throttle valve position sensor
Stepper
Coolant temperature sensor
Intake air temperature sensor
Intake system cleaning Air filter
Diffuser and throttle valve
Supplementary air pipe and Stepper
Intake system seal (seepage) Intake manifold - head
Throttle body - manifold
Intake sleeve
Filter housing
Fuel system (low pressure) Fuel pump
Pressure regulator
Fuel filter
Injector flow
Engine does not rev down
ENGINE DOES NOT RETURN TO IDLING/IDLING TOO HIGH

HV coil
Injector
Air temperature
Coolant temperature
Ignition efficiency Ignition timing
Stepper
Intake sleeve
Filter housing
Pressure regulator
Fuel filter
Injector flow
INJEC - 141
Exhaust backfires in deceleration
EXHAUST BACKFIRING WHEN DECELERATING

HV coil
Injector
Air temperature
Coolant temperature
Lambda Probe
Stepper
Intake sleeve
Filter housing
Pressure regulator
Fuel filter
Injector flow
Exhaust system seal (seepage) Manifold - head
Manifold - silencer
Silencer welding
Engine revs irregularly
REGULAR ENGINE PROGRESS WITH VALVE SLIGHTLY OPEN

Intake system cleaning Air filter
Diffuser and throttle valve
Supplementary air pipe and Stepper
Intake system seal Intake sleeve
Filter housing
Ignition system Spark plug wear check
Parameter reliability Throttle valve position signal
Coolant temperature signal
Intake air temperature signal
Ignition advance
TPS reset successful TPS reset successful
HV coil
Injector
Air temperature
Coolant temperature
Lambda Probe
Poor performance at full throttle
POOR ENGINE PERFORMANCE AT FULL POWER/ IRREGULAR ENGINE PROGRESS

ON ACCELERATION
HV coil
Injector
Air temperature
Coolant temperature
INJEC - 142

Lambda Probe
Power to spark plug Spark plug
Shielded cap
HV Cable
HV Coil
Intake system Air filter
Filter housing (seal)
Intake sleeve (seal)
Ignition advance
Fuel system Fuel level in the tank
Fuel pressure
Fuel filter
Injector flow
Engine knocking
PRESENCE OF KNOCKING (COMBUSTION SHOCKS)

HV coil
Injector
Air temperature
Coolant temperature
Lambda Probe
Ignition efficiency Spark plug
Ignition advance
Intake system seal Intake sleeve
Filter housing
TPS reset successful TPS reset successful
Fuel system Fuel pressure
Fuel filter
Injector flow
Fuel quality
Selecting the thickness for the cylinder base gasket Selecting the thickness for the cylinder base gasket
Fuel supply system
The fuel system circuit includes the electric pump, the filter, the pressure regulator, electro-injector and
pipes.
The electrical pump is located in the tank from which the fuel is pumped and sent to the injector through
the filter.
The pressure is controlled by the pressure regulator situated in the pump assembly in the tank.
INJEC - 143
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
13.Joint
14.Fuel pipe
15.Clamp
16.Wiring clip
17.Throttle body / Control unit
INJEC - 144
Removing the injector
• 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
Removing the butterfly valve

• Cut the clamp.
• Release the control unit fixing lever.
• Undo and remove the cable grommet

fixing screw.
• Open the cable grommet fins.
• Disconnect the fast-release fitting of

the fuel.
• Disconnect the fuel injector connector.
• Undo and remove the three screws fix-

ing the manifold to the cylinder head.
INJEC - 146
• 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
seat in the throttle body fin, as shown in the pho-
tograph.
INJEC - 147
Fuel pump and filter check
FUEL PUMP REMOVAL

• Disconnect the fuel pump connector.
• Disconnect the fuel pipe.
• Unscrew the ring nut.

• Remove the fuel pump together with
rubber gasket from the tank.
FUEL PUMP INSTALLATION
• Insert the fuel pump together with plas-

tic gasket in the tank.
• Align the reference on the pump with
the one on the fuel tank.
WRONG POSITIONING OF THE FUEL PUMP MAY CAUSE

THE BLOCK OF THE FUEL LEVEL SENSOR.
INJEC - 148
• 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
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.
Pre-calibration ensures optimal air flow for the control of the idle speed.
This regulation must not be tampered with in any way whatsoever.
The injection system will complete the management of the idling through the Stepper and the variation
of the ignition advance.
After the pre-calibration the throttle body has an open valve with a variable angle depending on the
tolerances of the machining of the pipe and the valve itself.
The valve position sensor can also have various fitting positions. For these reasons the mVs of the
sensor with the valve at idle can vary from one throttle body to another.
To obtain the optimum carburetion, especially at small openings of the throttle valve, it is essential to
match the throttle body with the control unit following the procedure known as TPS resetting.
With this operation we inform the control unit, as a starting point, of the mV value corresponding to the
pre-calibrated position.
To reset, proceed as follows.
Connect the Axone following the specific instructions.

Shift to «ON».
INJEC - 150
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)
Make sure that the throttle valve control is in con-

tact with the stop screw.
Guaranteeing that this position will be kept, give the confirmation for the TPS reset procedure.
Reset should be performed in the following cases:

- on first fitting.
- if the injection control unit is replaced.
NOTE
THE TPS RESETTING PROCEDURE MUST NOT BE CARRIED OUT WITH A USED THROTTLE
BODY BECAUSE POSSIBLE VALVE WEAR AND STOP WEAR FOR THE MINIMUM OPENING
MAKE THE AIR FLOW DIFFERENT FROM THAT OF THE PRE-CALIBRATION.
INJEC - 151
INDEX OF TOPICS
SUSPENSIONS SUSP
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. Spacer
10. Oil seal
11. Odometer gear
12. Pulling element
13. Spacer
CAUTION
SET THE SUPPORT UNDER THE VEHICLE IN SUCH A WAY THAT THE FRONT WHEEL HAS FREE
SPACE TO MOVE AND THE VEHICLE IS FIRMLY SECURED FROM FALLING.
SUSP - 153
Suspensions SCARABEO 125 i.e. - 200 i.e.
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. OTHERWISE, THE CALLIPER
PLUNGERS COULD GO OUT OF THEIR SEAT, RESULTING
IN BRAKE FLUID LEAKAGE.

M6 screw fixing front wheel axle clamp 10 (7.4 lbf
ft)
• Unscrew and remove the wheel axle.

Wheel axle fixing screw 50 (37 lbf ft)
• Remove the wheel being careful with

the odometer movement sensor «1».
SUSP - 154
• 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.
• Remove the left oil seal «3».
• Remove the left bearing «4» with a
suitable extractor.
• Carry out a thorough check of the bear-
ings.
• Collect the internal spacer «5».
• Clean the inside of the hub thoroughly.
• Wash all the parts with clean deter-
gent.
CAUTION
UPON REFITTING, USE A BUFFER WITH A DIAMETER
EQUAL TO THE EXTERNAL RING OF THE BEARINGS TO
INSERT THE BEARINGS. DO NOT HIT THE BALLS AND/OR
THE INTERNAL RING. MAKE SURE THE FOLLOWING
COMPONENTS ARE FITTED PERFECTLY IN:
• THE LEFT BEARING «4» ON THE HUB;
• THE SPACER «5» ON THE LEFT BEARING
«4»;
• THE RIGHT BEARING «2» ON THE SPACER
«5»;
SUSP - 155
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.
GASKETS
Check that the gaskets are in good conditions; replace them if they show signs of damage or excessive
wear.
WHEEL AXLE
Using a dial gauge, check the wheel pin «2» ec-
centricity. Replace the pin «2» if the eccentricity
exceeds the limit value.
Characteristic
Maximum eccentricity:
0.25 mm
WHEEL RIM
Using a dial gauge, check that the radial eccen-
tricity «A» and the axial eccentricity «B» of the
wheel rim «3» do not exceed the limit value.
An excessive eccentricity is usually caused by
worn or damaged bearings.
Replace the wheel rim «3» if, after the bearings are
replaced, the value is not within the specified limit.
Characteristic
Maximum radial and axial eccentricity:
2 mm
SUSP - 156
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. CHECK THAT THE INFLATION
VALVES «1» HAVE THEIR CAPS FITTED IN ORDER TO
AVOID UNEXPECTED FLAT TYRES.
BALANCE THE WHEEL AFTER A TYRE IS MENDED.
Front fork
Front fork diagram
key:
1. M10x30 screw
2. Sealing washer
3. Right sleeve
4. Left sleeve
5. Bottom buffer
6. Stem
7. Counter spring
SUSP - 157
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.
• Loosen the two upper screws fixing the

fork stem.
• Remove the upper retainer «2».

• Remove the wheel holder stem «3» by
pulling it from the below.
SUSP - 158
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.
• Slide off the pumping member pin «2»

from the stem and collect the spring
«3».
• Slide off the dust guard «4» from the

sleeve.
SUSP - 159
• 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.
Oil emptying
NOTE
BEFORE CARRYING OUT THE FOLLOWING OPERATIONS GET A CONTAINER WITH SUITABLE
CAPACITY TO COLLECT THE OIL.
SUSP - 160
• 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».
• Remove the seeger ring «2».
• Remove the cap «1» together with the

O-ring.
• Remove the spring«3» and wait some

minutes so that the oil deposited on it
drips off.
SUSP - 161
• 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).
• If the scorings are deep, replace the stem.
• Use a dial gauge to check that the stem bending is below the limit value.
• If over the value, replace the stem.
CAUTION
A BENT STEM SHOULD NEVER BE STRAIGHTENED BECAUSE ITS STRUCTURE WOULD BE

WEAKENED AND USING THE VEHICLE MAY BECOME DANGEROUS.
Characteristic
Bending limit:
0.2 mm
Sleeve
• Check that there are no damages and/

or cracks; otherwise, replace it.
• If there are signs of excessive wear or
damage, replace the affected compo-
nent.
Replace the following components with new ones:

- O-ring gasket on the cap «1»;
SUSP - 162
- 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.
NOTE
SPREAD A THIN LAYER OF FORK OIL ON GASKETS AND
BUSHINGS BEFORE REFITTING THEM.
• Insert the washer.
• Insert the oil seal.
SUSP - 163
• 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
• 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.
CAUTION
NEVER REUSE OIL.
• Fit the spring.
SUSP - 165
• 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» and on the fixed seat «3» is not damaged
or too worn. Replace the whole bearing if neces-
sary.
CAUTION
CHECK THAT THE COMPONENTS ARE IN GOOD CONDI-
TIONS.
CAUTION
APPLY GREASE ON BALL CONTACT AREAS ON BOTH
SEATS «2» AND «3».
Rear
SUSP - 166
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:
• Remove the silencer.

• Remove the rear brake calliper.
SUSP - 167
• 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.

• Unscrew and remove the two front

bolts «1» fixing the plate and collect the
nuts and the washers.
• Remove the right suspension plate.

Screw fixing the silencer plate to the engine 25
(18.5 lbf ft)
• Collect the wheel spacer.

• Remove the entire rear wheel together
with the brake disc.
CAUTION
DO NOT ACTUATE ON THE REAR BRAKE LEVER AFTER
REMOVING THE WHEEL, OTHERWISE THE CALLIPER
PLUNGER COULD GO OUT OF ITS SEAT, RESULTING IN
BRAKE FLUID LEAKAGE.
SUSP - 168
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:
• Remove the tail fairings.

NOTE
GET A HOIST AND BELTS FOR LIFTING.
• Fasten the belts to the chassis rear
section.
• Lift the hoist arm until the belts are taut.
• Working from both sides of the vehicle,

undo the upper screw «1» fixing the
shock absorbers.

M8 upper screw fixing shock absorber 25 (18.5 lbf ft)
SUSP - 169
• Working from both sides of the vehicle,

undo the lower screw fixing the shock
absorbers.
• Remove the shock absorbers.

M10 lower screw fixing shock absorber 50 (37 lbf ft)
Exhaust bracket
To remove the silencer plate, proceed as follows:
• Remove the silencer.
• 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.

SUSP - 170
• Unscrew and remove the two front

bolts «1» fixing the plate and collect the
nuts and the washers.
• Remove the right suspension plate.

Screw fixing the silencer plate to the engine 25
(18.5 lbf ft)
Centre-stand
CAUTION
ALLOW ENGINE AND EXHAUST SILENCER TO COOL OFF.
SECURE THE vehicle SO THAT IT IS POSSIBLE TO OPERATE IN TOTAL SAFETY AND WITHOUT
THE SIDE STAND.
To remove the centre stand together with its sup-
port, proceed as follows:
• Make sure the vehicle is still supported,

without the help of the centre stand.
• Undo and remove the two screws «1»
from both sides.
• Remove the centre stand together with
its support.

M8 screw fixing screw stand support to engine 25 (18.5 lbf ft)
To remove the centre stand from its support, pro-
ceed as follows:
• Make sure the vehicle is still supported,

without the help of the centre stand.
• Remove the springs «2» from the
spring linking pins «3» from both sides.
• Undo and remove the screw «4» from
both sides.
• Remove the stand.

M10 screw fixing stand to stand support 50 (37 lbf ft)
SUSP - 171
INDEX OF TOPICS
BRAKING SYSTEM BRAK SYS

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.
• Remove the brake disc.
CAUTION
UPON REFITTING, APPLY THE RECOMMENDED PROD-
UCT ON THE BRAKE DISC SCREW THREADS.
LOCTITE® 243 Loctite adhesive to assemble
cylindrical pieces
Loctite adhesive to assemble cylindrical pieces
BRAK SYS - 173

Braking system SCARABEO 125 i.e. - 200 i.e.
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. Replace the disc if the minimum thickness, even at a single point of the disc,
is less than the minimum value.
CAUTION
OPERATIONS TO BE CARRIED OUT WITH BRAKE DISC FITTED ON THE WHEEL.
Characteristic
Minimum value for brake disc thickness:
3.6 mm
• Using a dial gauge, check that disc os-

cillation does not exceed the tolerance;
otherwise, replace it.
Characteristic
Brake disc oscillation tolerance:
0.3 mm
Front brake disc
Removal

• Undo and remove the five brake disc
screws.
• Remove the brake disc.
NOTE
TIGHTEN ALL THE SCREWS MANUALLY WORKING DI-
AGONALLY
CAUTION
UPON REFITTING, APPLY THE RECOMMENDED PROD-
UCT ON THE BRAKE DISC SCREW THREADS.
LOCTITE® 243 Loctite adhesive to assemble
cylindrical pieces
Loctite adhesive to assemble cylindrical pieces
Disc Inspection
• Carry out a visual inspection of brake disc surface. Replace the disc if scored or deteriorated.
BRAK SYS - 174

• 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.
CAUTION
OPERATIONS TO BE CARRIED OUT WITH BRAKE DISC FITTED ON THE WHEEL.
Characteristic
Minimum value for brake disc thickness:
3.6 mm
• Using a dial gauge, check that disc os-

cillation does not exceed the tolerance;
otherwise, replace it.
Characteristic
Brake disc oscillation tolerance:
0.3 mm
Front brake pads
Removal
• Remove the front brake calliper by un-

screwing the two bolts «1».

M8 screw fixing front brake calliper 25 (18.5 lbf ft)
• Unscrew and remove the threaded cap

«2».
BRAK SYS - 175

• 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.
CAUTION
ALWAYS REPLACE BOTH PADS AND MAKE SURE THEY
ARE CORRECTLY POSITIONED INSIDE THE CALLIPER.
To refit, follow the steps but in reverse order.
Rear brake pads
Removal
• Remove the rear brake calliper by un-

screwing the two bolts «1».

M8 screw fixing rear brake calliper 25 (18.5 lbf ft)
• Remove the Seeger ring.
BRAK SYS - 176

• 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.
• Fit the spring.
• Refit the pin.
• Insert the Seeger ring.
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.
CAUTION
ALWAYS REPLACE BOTH PADS AND MAKE SURE THEY

ARE CORRECTLY POSITIONED INSIDE THE CALLIPER.
Fill - Bleeding the braking system
Rear - combined
CAUTION
CONSIDERING THE DANGER FOR VEHICLE AND RIDER, IT IS STRICTLY NECESSARY, AFTER
REFITTING BRAKES AND RESTORING THE BRAKING SYSTEM TO THE REGULAR USE CON-
DITIONS, THAT THE HYDRAULIC CIRCUIT BE AIR PURGED.
BRAK SYS - 177

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» of the front brake calliper and on the rear
brake calliper.
Front brake
• Remove the rubber protection cover of

the bleeding valve «3».
• Insert a transparent plastic pipe in the
bleeding valve «3» of the front brake
calliper and insert the other end of this
pipe into a container to collect the fluid.
• Quickly press and release the front
brake lever several times and then
keep it fully pressed.
• Loosen the bleeding valve 1/4 of a turn
so that the brake fluid flows into the
container. This will release tension on
the brake lever and will make it go to
the end of stroke.
• Repeat the operation until the fluid
draining into the container is air-bubble
free.
NOTE
WHILE PURGING THE HYDRAULIC SYSTEM, FILL THE
RESERVOIR WITH THE NECESSARY QUANTITY OF
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.
• Refit the rubber protection cover.
BRAK SYS - 178

REAR BRAKE

bleeding valve «4» of the rear brake
• Quickly press and release the rear
brake lever several times and then
keep it fully pressed.
• Loosen the bleeding valve 1/4 of a turn
so that the brake fluid flows into the
container. This will release tension on
the brake lever and will make it go to
the end of stroke.
• Repeat the operation until the fluid
draining into the container is air-bubble
free.
NOTE
WHILE PURGING THE HYDRAULIC SYSTEM, FILL THE
RESERVOIR WITH THE NECESSARY QUANTITY OF
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.
BRAKE FLUID CHANGE
• Remove the rubber protection cover.

• Insert a transparent plastic pipe on the
bleeding valve «1-2» of the calliper and
insert the other end of the pipe into a
container to collect the fluid.
• Loosen the bleeding valve «1-2» ap-
proximately one turn.
NOTE
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.
BRAK SYS - 179

• 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.
• Check the fluid coming from the pipe
and when the fluid changes colour
(from dark to light), tighten the bleeding
valve «1-2» and remove the pipe.
• Top-up the oil in the reservoir up to the
correct level.
Front

bleeding valve «1» of the front brake
• Quickly press and release the brake
lever of the specific brake calliper sev-
eral times and then keep it fully press-
ed.
• Loosen the bleeding valve «1» of 1\4 of a turn so that the brake fluid flows into the container.
This will release tension on the brake lever and will make it go to the end of the stroke.
• Repeat the operation until the fluid draining into the container is air-bubble free.
NOTE
WHILE PURGING THE HYDRAULIC SYSTEM, FILL THE RESERVOIR WITH THE NECESSARY
QUANTITY OF BRAKE FLUID. CHECK THAT, DURING THE OPERATION, THERE IS ALWAYS
BRAKE FLUID IN THE RESERVOIR.
• Tighten the bleeding valve «1» and remove the pipe.
• Top-up the oil in the front brake reservoir up to the correct level.
BRAK SYS - 180

INDEX OF TOPICS
COOLING SYSTEM COOL SYS

Cooling system SCARABEO 125 i.e. - 200 i.e.
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. Pump-radiator pipe
12. Clamp
13. Breather pipe
14. Clamp
Coolant replacement
Emptying
NOTE
USE A CONTAINER OF ADEQUATE CAPACITY TO COLLECT THE FLUID THAT MAY LEAK DUR-
ING OPERATION.
COOL SYS - 182

SCARABEO 125 i.e. - 200 i.e. Cooling system

• 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.
Filling
• Reposition the coolant delivery pipe

and tighten with a clamp.
• Top-up the expansion tank with cool-
ant until the fluid level reaches the
"MAX" reference mark.
• Top-up the radiator with coolant until it
is full and close the snap-on cover.
• Set the vehicle into motion and let the
engine idle until the fan switches on.
• Shut off the engine and let it cool down
for 12 hours.
• Check the level at both the expansion
tank and the radiator; fill up to the cor-
rect level if required.
• Refit the front shield.

Coolant piping clamp retainers 3 (2.22 lbf ft)
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.
COOL SYS - 183

Cooling system SCARABEO 125 i.e. - 200 i.e.
• Working from the flywheel cover inter-

nal side, remove the safety ring.

nal side, remove the shaft of the pump
together with the rotor using a rubber
mallet.

nal side and using an extractor, re-
move the water pump bearing.
• Working from the flywheel cover internal side and being careful not to damage the seat,
remove the oil seal.
WATER PUMP CHECK

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. Replace them if they are.
GASKETS Check that the O-ring is in good conditions; replace it if damaged or worn.
BEARINGS Manually rotate the internal ring which must turn smoothly, without obstacles and/or noise.
There must be no axial clearance. The bearings presenting these problems must be replaced.
COOL SYS - 184

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
020456Y 24 mm Ø punch
020455Y 10-mm guide for oil seal on water
pump shaft
• Fit the bearing working from the fly-
wheel cover internal side and using the
specific special tool.
Specific tooling
020456Y 24 mm Ø punch
020455Y 10-mm guide for oil seal on water
pump shaft
• Working from the flywheel cover exter-
nal side, fit the contacting seal using
the specific special tool.
Specific tooling
020700Y Water seal punch
• Once a small quantity of Loctite 603 is applied on the bearing inner track, fit the pump shaft
together with the rotor, working from the cover external side.
CAUTION
MAKE SURE NO LOCTITE COMES INTO CONTACT WITH THE BALLS
• Working from the flywheel cover internal side, lock every element with the safety ring.
• Fit the water pump cover and tighten the 3 screws at 6 Nm.
See also
Top-up
Level check
Refitting the flywheel cover
COOL SYS - 185

INDEX OF TOPICS
CHASSIS CHAS
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.
• Unscrew the four nuts «1».
• Undo the two screws «2».
• Remove the saddle.

M6 nut fixing saddle hinge to saddle 6 (4.44 lbf
ft) Saddle to saddle hinge M6 fixing screw 4
To remove the hinge from the saddle, proceed as

follows:
• Remove the saddle.

• Remove the cotter pin «3» and slide off
the pin.
Rear rack
• Unscrew and remove the four screws
«1».
• Remove the luggage rack.
CAUTION
HOLD THE LUGGAGE RACK WHILE UNDOING THE

SCREWS.

Rear passenger grab handle M8 fixing screw
25 (18.5 lbf ft)
Driving mirrors
Park the vehicle on its centre stand.

NOTE
THE REAR-VIEW MIRRORS ARE THREADED:
RIGHT (LEFT REAR-VIEW MIRROR);
LEFT (RIGHT REAR-VIEW MIRROR).
CHAS - 187
Chassis SCARABEO 125 i.e. - 200 i.e.
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».
Unscrew and remove the rear-view mirror «1» (an-
ticlockwise for the left rear-view mirror, clockwise
for the right one).
CAUTION
HOLD THE REAR-VIEW MIRROR "1" TO AVOID DROPPING
IT BY ACCIDENT.
When refitting the bulb:

Screw the rear-view mirror «1» at least three turns (clockwise for the left rear-view mirror, anticlockwise
for the right one).
Set the rear-view mirror «1» in order to achieve the best view angle.
Lock the rear-view mirror «1» in position acting on the lock nut «2» (clockwise for the left nut, anti-
clockwise for the right one).
NOTE
THE RIGHT LOCK NUT HAS A SCORING TO DISTINGUISH IT FROM THE LEFT ONE.
Instrument panel
• Use a screwdriver to remove the caps

«1».
CHAS - 188
• 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.
• Undo the two screws «6» from both

sides and release the instrument panel
from the rear handle cover.
CHAS - 189
• 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
remove the screw «4» from both sides.
• Remove the headlamp; be careful not
to damage it.
CHAS - 190
Legshield
• Unscrew and remove the four screws

«1».

• Slightly lift the shield front section and
remove it by sliding it off from the
tongues.
CAUTION

DO NOT DAMAGE THE TABS AND/OR THEIR CORRE-
SPONDING SLOTS.
HANDLE PLASTIC AND PAINTED COMPONENTS WITH
CARE, DO NOT SCRATCH OR SPOIL THEM.
NOTE
UPON REFITTING, INSERT THE FITTING TABS CORRECT-

LY IN THEIR SLOTS.
Knee-guard
To remove the leg shield back plate, proceed as follows:

• Remove the front side fairings.
• Undo and remove the central screw

«1».
CHAS - 191
• 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.
• Remove the spark plug inspection cover.
• Remove the mats.
CHAS - 192
• Undo and remove the screw «1» from

both sides.

«2» and the two screws «3» from both
sides.
located at the bottom of the footrest,
from both sides.
• Slide off the footrest.
Side fairings
To remove the front side fairings, proceed as fol-

lows:

• Working from both sides, undo the
screw «1» and the eight screws «2».
CHAS - 193
• Remove the fairing by releasing it from its fixing tongues.

CAUTION

DO NOT DAMAGE THE TABS AND/OR THEIR CORRESPONDING SLOTS.
HANDLE PLASTIC AND PAINTED COMPONENTS WITH CARE, DO NOT SCRATCH OR SPOIL
THEM.
NOTE
UPON REFITTING, INSERT THE FITTING TABS CORRECTLY IN THEIR SLOTS.
Air filter
• Operating from the left side, undo and

remove the fixing screws and collect
the washers.
• Loosen the clamp fixing the throttle

body manifold to the air filter box.
CHAS - 194
• Remove the air filter box and discon-

nect the oil vapour recovery pipe.
• Remove the air filter box.
Tail guard

• Remove the rear luggage carrier.
• Working from both sides undo and re-

move the screw «1».
• Undo and remove the five screws «2»,

two on the right side and three on the
left side of the vehicle.
CHAS - 195
• 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:
• To remove the license plate holder, un-

do the three screws «1» and collect the
nuts.

and collect the nuts.
CHAS - 196

«3».
• Disconnect the connector of the li-
cense plate holder light and remove
the mudguard.
Helmet bay

• Remove the rear luggage carrier.
• Remove the spark plug inspection cover.
• Unscrew and remove the fuel tank cap.

and the two screws «2».
• Remove the two screws «6».
CHAS - 197

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.
• Remove the helmet compartment to-

gether with the saddle by detaching it
from the rubber protection.
CHAS - 198
Fuel tank

• 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.
CHAS - 199
• 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).
• Disconnect the pipes from the radiator.
• Undo and remove the screw «1» fixing

the radiator.

M6 fixing screw for radiator (on plastic) 6 (4.44
lbf ft)
CHAS - 200
• 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
• Empty the cooling system (SEE COOLANT CHANGE).

• Remove the front shield.
• Remove the front side fairings.

• Release the expansion tank from the
pipe.

M6 screw fixing expansion tank 4 (2.96 lbf ft)
CHAS - 201
INDEX OF TOPICS
PRE-DELIVERY PRE DE
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
engine - chassis retainers
steering assembly
- Plastic parts fixing screws
Electrical system
- Main switch
- Headlamps: high beam lights, low beam lights, tail lights (front and rear) and their warning lights
- Headlight adjustment according to regulations in force
- Front and rear stop light switches and their bulbs
- Turn indicators and their warning lights
- Instrument panel lights
- Instrument panel: fuel and temperature indicator (if present)
- Instrument panel warning lights
- Horn
- Electric starter
- Engine stop via emergency stop switch and side stand
- Saddle electric opening switch (if present)
PRE DE - 203
Pre-delivery SCARABEO 125 i.e. - 200 i.e.
- 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.
CAUTION
TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE.

INADEQUATE CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFORE
IT IS FIRST USED SHORTENS BATTERY LIFE.
CAUTION
UPON INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEG-
ATIVE ONE, AND PERFORM THE REVERSE OPERATION UPON REMOVAL.
WARNING
THE BATTERY ELECTROLYTE IS POISONOUS AS IT MAY CAUSE SERIOUS BURNS. IT CON-

TAINS SULPHURIC ACID. AVOID CONTACT WITH YOUR EYES, SKIN AND CLOTHING.
IN CASE OF CONTACT WITH YOUR EYES OR SKIN, WASH WITH ABUNDANT WATER FOR AP-
PROX. 15 MIN. AND SEEK MEDICAL ATTENTION IMMEDIATELY.
IF ACCIDENTALLY SWALLOWED, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR
VEGETABLE OIL. SEEK IMMEDIATE MEDICAL ATTENTION.
BATTERIES PRODUCE EXPLOSIVE GASES; KEEP CLEAR OF NAKED FLAMES, SPARKS OR
CIGARETTES. VENTILATE THE AREA WHEN RECHARGING INDOORS. ALWAYS WEAR EYE
PROTECTION WHEN WORKING IN THE PROXIMITY OF BATTERIES.
CAUTION
NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY. USING
A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE
A FIRE.
Levels check
- Hydraulic braking system fluid level
- Rear hub oil level
- Engine coolant level (if present)
- Engine oil level
- Mixer oil level (if present)
Road test
- Cold start
- Instrument panel operation
- Response to throttle control
- Stability when accelerating and braking
PRE DE - 204
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)
Functional inspection
- Hydraulic braking system

- Brake levers stroke
- Clutch - Check for correct operation
- Engine - Check for correct general operation and absence of abnormal noise
- Other
- Documentation check:
- Chassis and engine numbers check
- Supplied tools check
- License plate fitting
- Locks checking
- Tyre pressure check
- Installation of mirrors and any possible accessories
NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES AS TYRES MAY BURST.

CAUTION
CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE.
PRE DE - 205
A
Air filter: 33, 194
B
Brake: 173–176
Brake disc: 173, 174
Brake pads: 175, 176
C
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
D
Display:
E
ECU: 65
Electrical system: 14, 43, 49, 203
Engine oil: 33
Exhaust: 68, 142, 170
F
Fairings: 193
Fork: 157
Front wheel: 153, 155
Fuel: 143, 148, 149, 199
Fuel pump: 148
H
Handlebar:
Headlight: 40, 190
Hub oil: 31
I
Identification: 12
Instrument panel: 188
Intermediate gear: 100, 124
M
Maintenance: 9, 29
Maintenance Table:
Mirrors: 187
Mudguard: 196
R
Radiator: 200
Rear wheel: 167
Recommended products:
S
Shock absorbers: 169
Side fairings: 193
Spark plug: 29
Stand:
Start-up:
Starter motor: 98, 102
T
Tank: 199, 201
Technical data:
Transmission: 14, 74, 88
Tyres: 15
W
Water pump: 183

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art vandelay reyiz, xmax kulübünden yılmaz ve erjan reyiz, tüm varyatör

alemi ve scarabeo dostlarına

SERVICE STATION MANUAL

SCARABEO 125 i.e. - 200 i.e.

SCARABEO 125 i.e. - 200 i.e.

THE VALUE OF SERVICE

ELECTRICAL SYSTEM ELE SYS

ENGINE FROM VEHICLE ENG VE

BRAKING SYSTEM BRAK SYS

COOLING SYSTEM COOL SYS

DO NOT DISPOSE OF FUEL INTO THE ENVIRONMENT.

KEEP OUT OF THE REACH OF CHILDREN.

TRANSMISSION OIL AND USED FORK OIL

IT IS ADVISABLE TO WEAR LATEX GLOVES WHEN CARRYING OUT SERVICE WORK.

DO NOT DISPOSE OF OIL INTO THE ENVIRONMENT.

KEEP OUT OF THE REACH OF CHILDREN.

KEEP OUT OF THE REACH OF CHILDREN.

THE BATTERY ELECTROLYTE IS TOXIC, CORROSIVE AND AS IT CONTAINS SULPHURIC ACID,

KEEP OUT OF THE REACH OF CHILDREN.

THE BATTERY LIQUID IS CORROSIVE.

GENERAL PRECAUTIONS AND INFORMATION

DO NOT DISCONNECT CONNECTORS BY PULLING THE CABLES.

DO NOT FORGET THAT TIGHTENING TORQUES OF ALL FASTENING ELEMENTS ON WHEELS,

FREEZING POINT C° (-°F)

These numbers are necessary for vehicle registration.

ALTERING IDENTIFICATION NUMBERS CAN BE SERIOUSLY PUNISHED BY LAW, PARTICU-

Dimensions and mass

WEIGHT AND DIMENSIONS

ENGINE TECHNICAL DATA

(*) Cannot be replaced

Frame and suspensions

CHASSIS AND SUSPENSION

Wheels and tyres

WHEELS AND TYRES

FRONT BODYWORK UNIT

CENTRAL BODYWORK UNIT

REAR BODYWORK UNIT

HEAD INSTRUMENT PANEL UNIT

ENGINE LINK ROD UNIT

BRAKING SYSTEM UNIT

EXHAUST SYSTEM UNIT

COOLING SYSTEM UNIT

ELECTRICAL SYSTEM UNIT

FUEL TANK UNIT

REAR SUSPENSION UNIT

REAR WHEEL UNIT

FRONT SUSPENSION UNIT

FRONT WHEEL UNIT

Cylinder - piston assy.

CYLINDER - PISTON COUPLING CLEARANCE 125 CM³

NAME ABBREVIA CYLINDER PISTON FITTING

CYLINDER - PISTON COUPLING CLEARANCE 200 CM³

NAME ABBREVIA CYLINDER PISTON FITTING

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