APRILIA scarabeo 125 i.e. Guide

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

SERVICE STATION
MANUAL
SCARABEO 125 i.e. - 200 i.e.
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
SCARABEO 125 i.e. - 200 i.e.
-Thismanualprovidesthemaininformationtocarryoutregularmaintenanceoperationsonyourvehicle.
- 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.Thesechangeswillbeintroducedinthesubsequenteditions of the manual. In case ofneed
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 Sectionsmarked 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

Rules
Safety rules
GENERAL PRECAUTIONS AND INFORMATION
When repairing, dismantling and reassembling the vehicle, follow the recommendations given below
carefully.
CAUTION
USEOFNAKEDFLAMESISFORBIDDENDURINGALL TYPES OFOPERATION.BEFORESTART-
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
EXHAUSTEMISSIONSCONTAINCARBONMONOXIDE, APOISONOUSGASWHICH CANCAUSE
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
SCARABEO 125 i.e. - 200 i.e. Characteristics
CHAR - 7

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
KEEP OUT OF THE REACH OF CHILDREN.
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
KEEP OUT OF THE REACH OF CHILDREN.
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,
Characteristics SCARABEO 125 i.e. - 200 i.e.
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
KEEP OUT OF THE REACH OF CHILDREN.
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
•Donot 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.
SCARABEO 125 i.e. - 200 i.e. Characteristics
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.
•Whentightening nutsand screws,start eitherfrom thecomponents withthelargest 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.
Characteristics SCARABEO 125 i.e. - 200 i.e.
CHAR - 10