LIST OF SECTIONS Introduetion Baoan eaten ery ‘repair and service the vehicle in detail ” This puicaton is intend er us by aprila dealers and ht tained, experercod mechanic ‘The devaripons of many sarvice andres opera tons nave been intently onstage sumed thatthe woos ols manual nave baie mecharia tring and basi knowledge othe prococuros Je for etor ves epalt aswell as sfey Fes reoes fo ensure the ally and that othe pubic wile Fapating mato vetcies Theta ts imerave that you o notte pater aiy mantenanee or eae procedure wth Sich you aro ra oughly ama sn ay aes {Spariom, Such an ate can result n delecive Tepats, which car be dange’eus both o you, toe ‘nme or use ofthe vent, andthe pola sinera, The lnoumation anita hs mara re Qinent a of te manuals aa of seu, She apila sp.a coninualy mpsoves is proaas, ‘hore mey become ctforoneastatweon tna veh cle you se servicing and tho stations and netusions ‘von h big manual youhave ary questions tout splat of ary eric recone oes ACS)AG:S Tocmiod Counselors wiloe ‘5b 19 asi you wih any problams you magn ace £5 wol's providing you wih lomaton or any Update and ternal changes othe vole You 2 ‘sorvcing. ‘ay changa made to tecrncal pactiations and ‘chide saving procedures wil be documented and ‘touted aprila dealers a ove the world. These Shanes we srr ner conse Pe prila spa. eserves height t madly spseoa tions and characorstes of ary otis mosate at sry _apriia makes ro representation that this manual overs avy such changes Fst tion: May 2001 Petco ana pinta Varb. Alger, 37/A- 500%2 Fornacete [) ‘a s38 Oar 23600 Facea er a z801 Ernai deat ‘Spala Sa eee General information H Routine maintenance operations Engine Fuel system Cooling system [ cectiaiysen Electrical system Cycle parts iCONTENTS Chapter 1 ‘SAFETY WARNINGS. PRECAUTIONS AND GENERAL INFORRATION REFITTING COMPONENTS USING THE MANUAL. POSITION OF SERIAL NUMBERS ‘SAFETY WARNINGS FOR FUEL, LUBRICANTS SOOLANT AND OTHER COMPONENTS. RUNNING.IN RULES POSITION OF THE WARNING ADHESIVE LABELS ‘CALIFORNIA EVAPORATIVE EMISSION SYSTEM. ‘SPARE PARTS. TECHNICAL DAA RECOMMENDED LUBRICANT. TOOLKIT GENERAL SPECIFICATIONS FOR TORGUE WAENGH SETTINGS ABBREVIATIONS / SYMBOLS /INTIALS Chapter 2 ROUTINE MAINTENANCE PLAN ‘SERVICING SCHEDULE LUBRICATION POINTS. ABRANGEMENT OF Teie WGTRUMENTS / COMTBOLS INSTRUMENTS AND INDICATORS BATTERY. SPARK PLUG IDLE ADJUSTMENT ADJUSTING THE THROTTLE CONTROL ‘AIR CLEANER CHECKING THE ENGINE GIL LEVEL AND TOPPING ib CHANGING THE ENGINE OIL AND THE ENGINE OIL FILTEa CHECKING THE TRANSMISSION OIL LEVEL. . CHANGING THE TRANSMISSION OIL, DISC BRAKES. FRONT BRAKE’ REAR BRAKE CHECKING THE BRAKE Pad WEA BLEEDING THE BRAKES: COOLANT, (CHANGING THE GOLAN. CHECKING THE STEERING. CHECKING THE SWINGING Aid PIVOT INSPECTING THE FRONT SUSPENSION INSPECTING THE REAR SUSPENSION WheELS, TORQUE WENCH SETTINGS TALE: Chapter 3 ENGINE COMPONENTS THAT CAN BE REMOVED WITHOUT REMOVING THE ENGINE REMOVING THE ENGINE FROM THE FRAME Chapter 4 MAINTENANCE DRAINING THE FUL TANK, REMOVING THE FUEL PUMP REMOVING THE FUEL LEVEL SENSOR CARBURETOR, 2001.05 Eadae 42 42 43 4 45Scarabeo 150 Chapter 5 DESCRIPTION, . 52 REMOVING THE RADIATOR : vn 38 REMOVING THE ELECTRIC COOLING Fad 33 REMOVING THE COOLANT 38 THERMAL SWITCH 54 REMOVING THE COOLANT THEANISTOA 55. REMOVING THE EXPANSION TANK THERMOSTAT VALVE. COOLANT PUMP Chapter 6 BuLas. CHANGING THE FRONT AND REAR DIRECTION INDICATOR BULBS. CHANGING THE HEADLIGHT BULES (CHANGING THE REAR LIGHT BULBS (CHANGING THE DASHBOARD BULBS CHANGING FUSES WIRING DIAGRAW. CHECKING THE RECHARGE SVSTEN 12 IGNITION SYSTEM (COOLANT TEMPERATURE GAUGE ELECTRIC COOLING FAN FUELLEVEL CIRCUIT CHECKING THE AUTOMATIC CHOKE (GOLB SiAR} SWITCHES CARBURETOR HEATER. CHECKING THE THERMAL SWi7GH.. (CHECKING THE PRESSURE SENSOR STARTER CIRCUIT TURN SIGNAL CIRCLiT HORN clacurT WIRING DIAGRA BRAKING LIGHTS GIAGUT UigHr ciRCUT UGHT CIRCUMT ex o> Chapter 7 ANTHTHEFT HOOK, UNLOCKING LOCKING THE SABOLE ‘SAFETY HELMET. REMOVING THE CENTRAL WNSBECTION COVER REMOVING THE SADDLE REMOVING THE GRASH HELMET CASE, REMOVING THE PARCEL GRID SUPPORT REMOVING THE FUEL TANK COVER (SADDLE COMPARTMENT) REMOVING THE REAR FAIRING. REMOVING THE REAR ARCH GLOVE COMPARTMENT. REMOVING THE INNER FRONT SHieiD REMOVING THE FRONT INSPECTION COVER REMOVING THE FRONT COVER REMOVING THE FRONT SHIELD REMOVING THE FOOTREST we REMOVING THE REAR FOOTAESTS REMOVING THE FLOOR PANEL LOWER GUARD REMOVING THE REAR-VIEW MIRRORS SRSRS SSRRRSRE eloase 00 2001-05,Scarabeo 150 REMOVING THE FRONT FAIRING. 79 REMOVING THE HEADLIGHT. 73 REMOVING THE TURN SIGNALS 743 REMOVING THE REAR LIGHT... : 714 REMOVING THE DASHBOARD PANEL . Ta REMOVING THE HEADLIGHT SUPPORT. 745 REMOVING THE HANDLEBAR COVER 75 REMOVING THE DASHBOARD. 76 REMOVING THE LEFT HANDLEBAR 7346 ELECTRICAL CONTROLS 7348 REMOVING THE EEE HANDLEBAR... @:5i:2““HasiieSar Tar ELECTRICAL CONTROLS. 77 REMOVING THE HANDLEBAR, 747 REMOVING THE FUEL TANK re REMOVING THE SADDLE LOCK 720 REMOVING THE IGNITION 720 SWITCHSTEERING LOCK 720 REMOVING THE AIR BOX 721 REMOVING THE EXHAUST BIDE : 721 REMOVING THE EXHAUST PIPE SUBBORT 722 REMOVING THE CENTER STAND. 722 FENOVING THE ENGINE CONNECTING OD oo soon 7-28 REMOVING THE FRONT MUDGUARD rea FRONT WHEEL. 728 REMOVING THE FRONT WHEEL ay CHANGING THE BEARINGS 728 REFITTING THE FRONT WHEEL oo 730 REAR WHEEL ts 731 REMOVING THE REAR WHEEL. 732 FRONT BRAKE. ents 738 (CHANGING THE BRAKE PADS 735 CHECKING THE BRAKE DISC. 738 REMOVING THE BRAKE DISC. 738 REAR BRAKE 737 STEERING... ee 738 INSPECTION OF THE BEARINGS ne 7.33 FEONT FORK : ral REMOVING THE FORK TUBES 742 DISASSEMBLING THE FORK 742 REFITTING THE FORK. 748 REAR SUSPENSION. 748 REMOVING THE REAR SUSPENSION : 749 2001.05,General information Beleace 09 2001.05General information Scarabeo 150 ‘SAFETY WARNINGS ‘Te ollowing precatlonary wamlags are used thoughout hs manu i dare convey the allowing message: Sefety warning. When you tind this symbol or the vehicle on the manual, be careful othe potontial ‘isk of personal injury. Non-compliance with te Inaatons given inthe messoges preceded by this symbol may recut in grave risks for Your and ather people's safely and for tho vehicle! Aware Inleates a potemal hazard which may reult in serous injury or even death AcautION Inaleates « potemtal hazard which may result in pesonalnjury or damage to the vehicle or other property. NOTE Tho word NOTE"in his manual prcedes imgorant infomation o Instutlons PRECAUTIONS AND GENERAL INFORMATION Keep strict tothe folowing instuctions when repaing, cisassmbing or eassenbing the motorcycle Awaroone Never use a naked flame for any operation whatsoever. Betore starting any servicing oF inspection Job onthe motorcycle, stop the engine, remove tho key, walt ‘ntl the engine and exhaust have cooled down ard, It possible, raise up tho motoreyete using the correct ‘equipment standing on a sold lovl floor. Be especialy careful about the parts ofthe engine and exhaust thatare stil hot, to avoid burs. Motoreyeto parts are not eae; donot bite, suck, chew or swallow any ofthe motorcycle parts fr any reason whatsoover Unless expressly stated othenise,fllow the dsacsembly steps in reverse order when reassembling ‘The overlapping of operations in references to other chapters must be Interpreted ina logical way, to avoid {he unnoceesary removal of components Never use the fuel as a solvent tack nthe motoreyote Disconnect the battery negative lod) If eloctic welding has tobe performed, ‘Aways be careful about the safety of the others when two or more people are working atthe same time. BEFORE DISASSEMBLY Remove alli, mud, dust and foin bodies trom the motocyce before removing ary companans When specied, use fe servic ook specaly designed forts marcy, DISASSEMBLY OF COMPONENTS Never ison andor tga ruts and bts wit lors cr other snr tools bays use a proper wrench Marthe posions of al unions and connections (hoses, wes, et) before aconnecing tm wth clearly sn guinabie mans. Each component most be coal markod 90 that teanbe identi or oting (lean and wash each emtoved component wi re pret solver aed components must be kpt together, 3s they become "matched" ator norms wear. Some paired components ‘must etherbe used togeter or bot paced. Felense 00 2001.05