APRILIA SCARABEO 125 User manual

SERVICE STATION MANUAL
854141
SCARABEO 125 - 200

SERVICE STATION
MANUAL
SCARABEO 125 - 200
The descriptions and illustrations given in this publication are not binding; While the basic characteristics
as described and illustrated in this manual remain unchanged, aprilia reserves the right, at any time and
without being required to update this publication beforehand, to make any changes to components, parts
or accessories, which it considers necessary to improve the product or which are required for
manufacturing or construction reasons.
Notallversionsshowninthispublicationareavailableinallcountries.Theavailabilityofindividualmodels
should be confirmed with the official aprilia sales network.
© Copyright 2008 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 - 200
NOTE Provides key information to make the procedure easier to understand and carry out.
CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.
WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.
Personal safety Failure to completely observe these instructions will result in serious risk of personal
injury.
Safeguarding the environment Sectionsmarked withthis symbolindicate the correct use ofthe 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
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
USEOFNAKEDFLAMESISFORBIDDENDURING ALL TYPESOFOPERATION.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 VEHICLE PARTS WITH YOUR MOUTH: VEHICLE
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
EXHAUSTEMISSIONS CONTAINCARBONMONOXIDE,APOISONOUSGASWHICHCANCAUSE
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
Characteristics SCARABEO 125 - 200
CHAR - 6

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,
SCARABEO 125 - 200 Characteristics
CHAR - 7

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 VEHICLE.
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 loosenand/or tightenscrews and nuts using pliersor anyother toolsthan thespecific
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.
Characteristics SCARABEO 125 - 200
CHAR - 8

•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 nuts andscrews,start eitherfrom thecomponentswith thelargest 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.
SCARABEO 125 - 200 Characteristics
CHAR - 9

•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 VEHICLE 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.
Characteristics SCARABEO 125 - 200
CHAR - 10

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
-30° (-22) Coolant 45% by volume
-40° (-40) Coolant 55% 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.
SCARABEO 125 - 200 Characteristics
CHAR - 11

CHASSIS NUMBER
Thechassisnumberisstampedonthefrontframe;
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
Specification Desc./Quantity
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 MODEL M287M (125) - MODEL M28B (200)
Specification Desc./Quantity
Model (125 ) M287M
Model (200) M28BM
Type (125 - 200) single-cylinder, 4-stroke with CVT
Engine capacity (125) 124.2 cm³ (7.58 cu.in)
Engine capacity (200) 180.8 cm³ (11.033 cu.in)
Engine revs at idle speed 1700 +/- 100 rpm
Cooling (125 - 200) Coolant
Compression ratio (125) 12: 1
Compression ratio (200) 11.6: 1
Valves per cylinder (125 - 200) 4
Bore / stroke (125) 58 x 47 mm (2.28 - 1.85 in)
Bore / stroke (200) 63 x 58 mm (2.48 - 2.28 in)
Maximum power to shaft (125) 9.5 kW at 9000 rpm
Maximum power to shaft (200) 13.3 kW at 8250 rpm
Maximum torque to shaft (125) 10.2 Nm at 8000 rpm
Maximum torque to shaft (200) 16.2 Nm at 6500 rpm
Characteristics SCARABEO 125 - 200
CHAR - 12

Specification Desc./Quantity
Overrevving limit (125 - 200) 10300
Valve clearance Inlet: 0.10 ÷ 0.15
Outlet: 0.15 ÷ 0.20
Valve angle (125 - 200) 15° intake - 18° outlet
Combustion chamber volume (125) 11.3 cm³ (0.69 cu.in)
Combustion chamber volume (200) 17 cm³ (1.037 cu.in)
Valve control (125 - 200) DOCH, with calibrated bowls
Timing system control (125 - 200) Morse chain, with hydraulic tensioner
Intake valve diameter (125) 21.9 mm (0.86 in)
Intake valve diameter (200) 23.2 mm (0.91 in)
Outlet valve diameter (125) 18.7 mm (0.74 in)
Outlet valve diameter (200) 20.2 mm (0.80 in)
Valve stem diameter (125 - 200) 4 mm (0.16 in)
Intake valve lift (125 -200) 7.2 mm (0.28 in)
Outlet valve lift (125 -200) 6.6 mm (0.26 in)
Intake diagram (at 1 mm - 0.039 in) - opening BTDC (125) 17° BTDC
Inlet diagram (at 1 mm - 0.039 in) - opening BTDC (200) 28° BTDC
Inlet diagram (at 1 mm - 0.039 in) - closure ABDC (125) 27° ABDC
Inlet diagram (at 1 mm - 0.039 in) - closure ABDC (200) 28° ABDC
Inlet diagram (at 1 mm - 0.039 in) - duration (125) 224°
Inlet diagram (at 1 mm - 0.039 in) - duration (200) 236°
Outlet diagram (at 1 mm - 0.039 in) - opening BBDC (125 -200) 28° BBDC
Outlet diagram (at 1 mm - 0.039 in) - closure ATDC (125 -200) 8° ATDC
Outlet diagram (at 1 mm - 0.039 in) - duration (125 -200) 216°
Connecting rod length (125) 101.5 mm (3.996 in)
Connecting rod length (200) 96 mm (3.78 in)
Cylinder (125 - 200) aluminium cylinder with nikasil coated treatment
Cylinder angle - short pitch (125 - 200) 10° with respect to the crankshaft - clutch axle assembly
Cylinder angle - long pitch (125 - 200) 18° with respect to the crankshaft - clutch axle assembly
Pin diameter (125 - 200) 15 mm (0.59 in)
Crankpin diameter (125 - 200) 28 mm (1.10 in)
Crankpin bushing (125 - 200) Ø 28 x 14 mm (1.10 in x 0.55 in)
Main journal diameter (125 - 200) 32.5 mm (1.28 in)
Main journal bushings (125 - 200) Ø 32.5 x 16.9 mm (1.28 in x 0.67 in)
Fuel supply system (125 - 200) with carburettor (EFI pre-installation in the head coupling)
Carburettor diameter (125): 26 mm (1.023 in)
Carburettor diameter (200): 26 mm (1.023 in) (optional: 30 mm - 1.180 in)
Air filter (125 - 200) paper
Petrol (125 - 200) unleaded, RON 95
Secondary air (125 - 200) pre-installation in the head coupling
Ignition system (125 - 200) Digital CDI, one M10 spark plug per cylinder
Ignition advance (125 - 200) max. 22° from 4500 to 9500 rpm
Generator - type (125 - 200) flywheel three-phase generator in oil - permanent magnet ex-
ternal rotor
Generator - output (125 - 200) 235 W at 8000 rpm
Lubrication system (125 - 200) wet sump
Oil pump(125 - 200) trochoidal - rotor unit external dimensions: Ø 28.9 x 10 mm
(1.14 in x 0.39 in)
Oil pump control (125 - 200) Morse chain, ratio: 0.68 (17 / 25)
Water pump (125 - 200) centrifugal rotor, Ø 35 mm (1.37 in)
Water pump control reduction ratio (125 - 200) Morse chain, ratio: 0.68 (17 / 25)
Thermostat (125 - 200) opening 80° + / - 2°
Start-up (125 - 200) electric with freewheel (no kick starter)
Starter motor (125 - 200) 0.6 kW
Start-up reduction ratio (125 - 200) 22.37 (59 / 9 x 58 /17)
Clutch (125 - 200) automatic centrifugal dry clutch
Chassis clamps (125 - 200) - ball bearings Inside diam.: 20 mm (0.79 in)
Shock absorber attachment (125) - silent-block Inside diam.: 10 mm (0.39 in)
Shock absorber attachment (200) Double retainer, Ø 8.5 mm (0.33 in) per bracket
Pick-up air gap 0.35 - 0.76 mm (0.0138 - 0.0299 in)
SCARABEO 125 - 200 Characteristics
CHAR - 13

Transmission
TRANSMISSION
Specification Desc./Quantity
Transmission (125 - 200) CVT with belt + final reduction unit
CVT ratio (125 ) 2.7: 1 - 0.84 1
CVT ratio (200) 2.2: 1 - 0.81: 1
Gear ratio - long pitch (125) 14 / 66 x 23 / 58
Gear ratio - short pitch (125) 14 / 47 x 15 / 47
Gear ratio - long pitch (200) 14 / 66 x 27 / 54
Gear ratio - short pitch (200) 16 / 45 x 15 / 47
Variator continuous, automatic
Primary drive V-belt
Secondary With gears
Engine/wheel total ratio (125) minimum: 32.1
maximum: 9.9
Engine/wheel total ratio (200) minimum: 21.0
maximum: 7.6
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)
-standarddiameter: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
Specification Desc./Quantity
Engine oil - engine oil change and engine oil filter replacement 950 cm³
Coolant 1.15 l (50% water + 50% ethylene glycol antifreeze fluid)
Seats 2
Vehicle max. load (rider + luggage) 115 kg (253.5 lb)
Vehicle max. load (rider + passenger + luggage) 210 kg
Engine oil quantity (125 - 200) 900 cm³ (54.92 in)
Transmission oil quantity (125 - -200) 200 cm³ (12.20 cu.in)
Electrical system
ELECTRICAL SYSTEM
Specification Desc./Quantity
Battery 12V - 10 Ah
fuses 20- 15- 15 A
(Permanent magnet) Generator 12V - 235 W
BULBS/WARNING LIGHTS
Specification Desc./Quantity
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
Characteristics SCARABEO 125 - 200
CHAR - 14

Specification Desc./Quantity
7 Turn indicator warning light (*) LED
8 High-beam warning light (*) LED
9 Low fuel warning light (*) LED
(*) Cannot be replaced
Frame and suspensions
CHASSIS AND SUSPENSIONS
Specification Desc./Quantity
Chassis type High-strength steel tubular chassis, single spar at the front, su-
perimposed double cradle at the rear.
Steering inclination angle 26.5°
Front suspension Hydraulic action telescopic fork
Front suspension travel 104 mm
Rear suspension hydraulic action double-acting shock absorber, adjustable pre-
loading
Rear suspension travel 80 mm
Brakes
BRAKES
Specification Desc./Quantity
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
Specification Desc./Quantity
Wheel Rims made of light alloy
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)
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)
SCARABEO 125 - 200 Characteristics
CHAR - 15

Name Torque in Nm
M5 screw fixing case to wheel housing 4 (2.96 lbf ft)
CENTRAL BODYWORK UNIT
Name Torque in Nm
Footrests to chassis fixing screw 4 (2.96 lbf ft)
M6 screw fixing battery access to footrest 4 (2.96 lbf ft)
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)
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)
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-
tion 2 (1.48 lbf ft)
Screw fixing instrument panel to headlamp panel, bottom sec-
tion, close to indicators 1 (0.74 lbf ft)
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 42 (31.08 lbf ft)
M8 safety screw for handlebar 20 (14.8 lbf ft)
ENGINE UNIT
Name Torque in Nm
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 to carburettor retainer 2 (1.48 ftlb)
Sleeve clamp on filter casing retainer 2 (1.48 lbf ft)
Characteristics SCARABEO 125 - 200
CHAR - 16

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)
M6 screw fixing brake pipe splitter to chassis 12 (8.88 ftlb)
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)
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)
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)
TANK UNIT
Name Torque in Nm
M6 screw fixing fuel tank to chassis (on plastic) 6 (4.44 ftlb)
M5 fixing nut for fuel level probe 6 Nm (4.44 lbf ft)
M6 screw fixing fuel pump to chassis 6 (4.44 ftlb)
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)
SCARABEO 125 - 200 Characteristics
CHAR - 17

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
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 EI fixing screws - M8x166 (4) 27 Nm + 90° (19.91 lbf ft + 90°)
Thermostat cover EI fixing screws - M6x20 (2) 10 Nm (7.38 lbf ft)
Head EI fixing screws (chain side) - M6x130 (2) 10 Nm (7.38 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 fixing screw - M18x10 (1) 35 Nm (25.81 lbf ft)
Chain tensioner guide slider EI fixing screws - M6 (1) 10 Nm (7.38 lbf ft) - Loctite 243
Transmission gear timing fixing screw - M8x20x1 (2) 27 Nm (19.91 lbf ft) - Loctite 243
Transmission oil drainage EI cap - M12x1.5 (1) 15 Nm (11.06 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 - M18x1.5 (1) -
Oil level cap - M16x1.5 (1) -
Crankcase EI fixing screws - M6x50 (2) 10 Nm (7.38 lbf ft)
Crankcase EI fixing screws - M6x70 (1) 10 Nm (7.38 lbf ft)
Ignition cover EI screws - M6x110 (5) 10 Nm (7.38 lbf ft)
Ignition cover EI screws - M6x140 (2) 10 Nm (7.38 lbf ft)
Ignition cover EI screws - M6x25 (1) 10 Nm (7.38 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)
CVT cover EI fixing screws - M6x35 10 Nm (7.38 lbf ft)
Transmission cover EI fixing screws - M6x30 (8) 10 Nm (7.38 lbf ft)
One-way clutch 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)
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) 80 Nm (59 lbf ft) - Loctite 243
CVT driving pulley fixing flanged pin - M10x25 35 Nm (25.81 lbf ft) - Loctite 243
Stator EI fixing screws - M6x25 (3) 10 Nm (7.38 lbf ft) - Loctite 243
Ignition sensor EI fixing screws - M5x12 (2) 6 Nm (4.42 lbf ft) - Loctite 243
Stator cable bracket fixing screw - M5x8 (1) 4 Nm (2.95 lbf ft) - Loctite 243
TEF screws fixing secondary aeration pipe to head - M6x20 (2) 10 Nm (7.38 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 TE screws - PT 1/8 (1) 10 Nm (7.38 lbf ft) - Loctite 573
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
Characteristics SCARABEO 125 - 200
CHAR - 18

Product Description Specifications
AGIP GREASE SM2 Lithium grease with molybdenum for
bearings and other points needing lubri-
cation
NLGI 2
AGIP BRAKE 4 Brake fluid FMVSS DOT4+
AGIP PERMANENT SPEZIAL Coolant Biodegradable coolant, ready for use,
with "long life" technology and character-
istics (pink). Freezing protection up to
-40°C. According to CUNA 956-16 stand-
ard.
SCARABEO 125 - 200 Characteristics
CHAR - 19

INDEX OF TOPICS
TOOLING TOOL