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REFITTING COMPONENTS ‘Acaurion Never use crip twice. When a circip is removed, I must be replaced with a new one. When assembiing ‘2 now circin, be careful not o stretch ts ends more than strictly necessary to pace ton the shat: Alter installing aeircip, make sure that itis completly and firmly ingorie in ts seat. NOTE bearings must un ely wih no sein ane neee, Replace bearings thal show any roughness when | the inner aces turned. Use any Origin! apria Spare Pans fo replacement. Use ony the recommended ibreants and sealing agent Lubricate all metal parts before refting ten Pay parulr ation to lbsicaeintral eng parts suchas piston ngs, valves, Uso propriotryassomoly bears whon appropiate. ‘When itoring ate and ble, start wih the lager slater or inet ones ane proseed in agonal ede Tighten em a gradual steps belore applying the al geting torque -Aays replace al gaskets, ctcips, snap ngs and O-ings. Replace sellocking ns I the feger torque allows the ‘ute be run ont ts matching Bo more han ore hal tur. Feplace the pis, stows andbots they are nicked, Crack, or rei any sign of tread darage. ‘Thoroughly clean al mating surlaoes blore reassemby. ‘ply atv fim of Khium-basee rosso ool sel rime ‘ways replace ol eal Upon reasomely, app fun fln of itum-basos grease te the seaing tip of aol sea before ta assembled overs mating sha (Chock to make sure that each component hasbeen fied proper ‘te cayng out pals or reutine sevicng, ge ough te ro-iecheckt thoroughly beer ing the motor: ‘le or allowing its be rdcen, Take ara un a parking oto other low vat area belore returning the moter ete to ts owner USING THE MANUAL HOW To CONSULT THE MANUAL This manuals vided inte chapters. Each chaser based on a catego of man comparens Fferto the MAIN CONTENTS" te Uniocs expres stated otter, flow the dsassemby step in reverse order when reassembling uns ‘Tha tora "ight and taro ntended ae to cers rh and let when sing inthe noma cing poston. CConesit he “USE AND MAINTENANCE handbook forinlematon onthe nema Use and serch ote motor eye | eciia | a Belongs 00__2001-05 2]General information Scarabeo 160 POSITION OF SERIAL NUMBERS ‘Thase rumbars are que for vehicle registration NOTE The aeration of he identi nue is ‘anofanes, punishabe wih eeminal and admit fe canst Ir pareuar, he aleaion ofthe ame umber wt result inmate invalgabon ofthe waranty VEHICLE IDENTIFICATION NUMBER (VAN) (FRAME NUMBER) Every vehicle produced by aprila receives vehis leorfcstion umber (V1.8) ‘onthe steering head fhe rama above ‘on the denis plate (B) which is cate onthe ont porn nea the staeing head fhe ta INFORMATION CONTAINED IN THE VEHICLE IDENTIFICATION NUMBER Deserpton ofthe vehicle identification number (V1 inion donseatengae ¥ Beloase 00 2101-05 cht(CARBURETOR ose EENORE lente as jaan corel 250 D3) [FUEL SUPE Hes Tae pa cy Tas eiy oad gacins win am acon ara Bae ot To GT a, TST — (SSRSOS. Fen aL pare SRS AE Sroka Tom (3a Fest TIS a aa hk saa WH OER IATL Whos =o osm (a (oRARES Fen “Se i OP (0. wi ya actin Fear bale 022) re (OBB Nin Nurase eUAtOT (EECA ry Tara Fen BsO LTC TRE. ripe baer Fen TO 1 sar ODE BI I NFUATION PRESSURE FOR SOLO RIDER. ont oo. OaTaT Spa [rear SOW 15027 5 pe [ont owe OTA ear Zeoa 22 eat Spe (eNO hs CI Tadao gran ig EEF blo 126 aR ‘CONTINUED > Release 00 2007.05‘Searabeo 160 (SPARK PLUG [Sandan TOK CREE=NOXOREE VE [Se pus 06-0. en(OLE- DOTA (eLEcTaIG eveTEN uses B15: 734 [cena st magoat 20 i00W [rt para ih 12: 3W restr vow [ues i ih c [Dae w2V-12W [aan Tighsar RECOMMENDED LUBRICANT Engine ol (ecommondod) EX SUPERBIKE 4, SAE EW. 40, ‘Asan aterabve ote recommenced os posse 0 use bigh- qual ofs wih characters In compliance ‘wih er suporer te be A® L Se. specications, ‘Transmission oll recommended): BFC, SAE 750 - 80. Azan atematva she rooammened o,f poste o Use igh- qual ots wth chaectersts in compianoe ‘sivorsuperor tobe AB SL# speciation Fork ol (recommended): FA. 5W or BF. A. 20W/or ol You'd an awh exerci charactenciesmcanparaon wih the BF. A, SW anc DF. A.20W or FORK Wane FORK EOW, these can be mixed as indicated blow: SAE 10W = IHF. A. SW 67% of the volume + IEF A. 20W 3994 of the volume SAE 15W= EEF A. SW 33% f the volume + ZF A Z0W 67% of he volume ‘Bearings and other ubrication points (recommended) 2 BINOL GRASE 451 ‘As an atematve fo the reconmensed produ, use high-quality grease fr roling beating, working tompraturo tage SOc. HO (2a eae) dpi pam a0". 2° GOR. 4), igh poecon apa ‘rosin, good relstarcs to walor and Sudaton Protection ofthe battery poles: neta grease oF vase, ‘Spray grease for chains (recommended): CHAINSPRAY. Brake fluid (recommended): {2 FF, DOT (Conpatbe DOT 4). “AWARWING Use new brake id ont. Use of used or contaminated brake fli can lead to brake fllure with subse- ‘quent acelden, serious injury. or even death Avannnic Use only antifreeze and anicorrosive witout nite, ensuring protection at least 26°C (31°F), Engine coolant (recommended): 32 ECOBLU - 40° 40°) or AGIP COOL. Fale to use aperomral attvoez, rived whats walor ae colar, can lado saious damage othe ‘motrevelescaoing stom, whlch can eause engine slave, and subsequent Upeel wth serous Inury or even lease 00 2001-05 ont | (EESGeneral information, ‘Scarabeo 150 TooL KIT The look (1) socatod in its own compartment under he sacle area. “To gain access tthe too: Lite sadce, see UNLOCKING / LOCKING THE ‘SADDLE, “The toot (1) cds: + 844mm (02n) Aen wrench 2); 4 18mm (06ir spre plug socket wrench 2) “a 3ockot roach hand (2: “an 8mm (0.3) and 10mm (04) combinaton ccketwrenen (5), - Scombinaton Pips / sloted sexensiver (8): + shock asusing spanner wrench 7); special socket wrench (8); + al pouch (3). GENERAL SPECIFICATIONS FOR TORQUE WRENCH SETTINGS “Te stands txque wench setings for sens and nls wits ISO me vena ar ven nthe able bol. The rue wrench etn strowor | wrenen | 7 or Ree) [Kae ra wa | sa) 0 we [sin | a8 Mo ve soe) [a0 we a _[sswos) [58 ae [ase | as we | worse) | ie Forte spocio slings fhe unions and courage fone moteeyele im quston, soe FASTENERS Unless otnervse specie, tho torque wrench stings ‘aero dean, cy toads a arbien emparaise. NOTE To avo detoming tie components, oF {ayia aleating nthe ho screws ard bot ae Fre screw nal te fasteners by han, Segond, ug fection o approaches ol he apa {erque seting wareng nthe Gageral pat ae ‘Stn, (0) ah (O-ring eo tener ‘prolt spocioseeuo, wating nthe sara oie [NOTE whon this procedures flowed the can ‘essure exerted byte fasteners wi be union) ‘Seinbted oer to srace of ojo cht Release 00 2001-05val Information ABBREVIATIONS / SYMBOLS / INITIALS al tp Wax, bor tan PH ua Noam. NORM. Rema « = ees than > greater han : ‘qual oor ess than > = ‘equal rarest than : appeosinatly = Finny So degrees Centirade sf 1 degrees Fatrennet : = plus or minus ac, = erating arent x Drnpore an Dmpere hour APL Armerican Polen iatte AT hightorsion i) bar uot pressure (1 bar= 100 kPa} Pet Internal state pressure ce, 7 dec curent (de) om cube centimeters co trmon manos oN Deuce ngustie Norm de. = area ouron rimin > Fevoutors por mine (pm) Ho tnburntryrocatoane 1SC > lle speed contol ig Rlogaams gm = blogyams por meter (1 kgm km homeo « = tion koa hioPasoal (1 KPa ~ 0.01 bar} kW 1 haha , Mere Foloase 09 2001.05 galons Tat eniting dose tetera second witoar ties pe nour mogaoh Motor mahod cctane ang 1 sResesc method ectane atra average of research ane mater octane ‘ang meved Nesom: (1 N= foot paunds foot cable ches inches ohm pec botlom dead cantar (200) {op deas contr (TDC) ‘evottons per minute ‘agnostic check fer soc crew ‘ted head eerew ma) psi down forks vot Wie cht |Routine maintenance operations Scarabeo 150 Routine maintenance operations ch.2 Release 00 2001.05Routi ‘Scarabeo 150 This socion doses the routine marserance proce gine em Dotaleraa nd ceoeerate the engine afew times make ure, when he trite returns tl, hat he longine ide speed i sil cored. ‘awarnn After you have adjusted the il, rotate the handle- bars fll eft and fl ight Chock o ensure that he bys. Algo check that he ttle smoothiyand {ly closes when released. ch.2 Belease 00 2001-05,‘Searabeo 150 ADJUSTING ‘THE THROTTLE CONTROL, Read carefully MAINTENANCE, Thi voile equipped with vo tote cbs. ‘The folowing rigematon may ero stone vote Awannne "the throtte sticks open, it may cause a colision wth anothor vob the throttle sticks, kl the engine with the engine stop switch located on the right handlebar. Do not attempt to restart the engine unt the throttle has been repaired and works perfectly Fallur to obey this warning can leadto a runeway with seriously injuries or even death. Wany fastener inthe trot system becomes os, ikewise you wil lose contol ofthis ve- fete. Ether situation can lead to an upset o colision with subsequent serious Injury or death “This vehicles equipped wih a double cable thot ne cable epons tte uote when you tao te thot grip toward you: he cnr clases te tote vwhon yu rota he gp away rom yous essen {al wien you lace te tote rp tht & automat tly etn to th ile poston ‘Ti couse eat arrangement enhances safely by rowing fa pete closing othe tate “AWARNNG In the event ofa throttle sticking emergency, tlvays kl he engine using ths engine stop ‘ule located near the tote grip on the ight handlebor Never use this vehicle If the throttle, ses a atemetiay ta aun oh ian when the tvatle gp ls released Fue to heed this waming can led to serious celdent and subsequent injury or even death. AcauTION Perform these maintonance operations at one- half ofthe spectiod interval, this veh ‘ten Used in rainy orvery dusty conatons, on ‘unpaved roads. ‘Cheek the tree cables ater the first 100 km (00 mi) and tereater every 6,000 kn (750 Mi. ‘The play ofthe tote cable must be between 2-3 sem (0.06 - 0.12, measured athe eage oft ap 500 the itaton above. Beleass 00 2001-05 en? (EERoutine maintenance operations To agustthe cable: Place the vehicle on ho center sta, (oe PLACING THE VEHICLE ON THE STAND}. Pull bac the rubber bet (1), Loosen the ck nut Fotato the adjustr (3) so aso provide to proper ‘Searanoe ‘Mor the adusimect,ghton the lock rut (2) and ‘heck he pay agai Replace the ter boot (1) peat he adustmant forthe second cable Awanunis Exhaust gases contain carbon monoxide, which is ‘extremely poisonous inhaled. Bo not start the engin in closed or badlyvert- (ed rooms. Fallure i observe this warning may cause loss of ‘consciousness o even load to death. Aware ‘Alter you have adjusted the throttle, rotate the ‘handtebars fl left end ful ight with he enghe atfocted by this. ‘Also check tat the trotle smoothly and uly loses when released. AIR CLEANER, Fadl carefully MAINTENANCE, “Aware Use only tre-prot solvent or mide detergest 0 ‘wash thea cloner. Awannoe esr rubber or ltex gloves whon servic Ing tho alr cloaner.Fallure to observe this waning ‘ca lead fo heath problems, Acaution Perform these maintenance operations at one- half ofthe spectegIntorvas, this vehicle ‘often used in rainy or very city condone, en tinpaved roads. Irspect hear leaner avery 6.000 km (3:70 or "iments of ue, to engure that & hae not become aged. ‘Tho a Gleaner must be inspect more Kequenty, loaned # necessary aod replaced moe equa tho vice cused on dusty or wot oad. More roquentoearing afte a eaneis sug fgoste, especialy your be is Used under very Susty concen. Evry 6.000 km (3,750 mi Femove the cena iain, (se8 REMOVING THE (CENTRAL FAIRING) ana crock seo ther ei. ‘or eartaminaton nthe Tower pat of te ra tue (1). Awa ‘Scarabeo 150 ch.2 Belease 00Routine maintenance 9} ‘Scarabeo 150 any contamination or i coming rom he ier ‘af tound lean the tbe a floes {aoson te stew ‘Wiha the cain ube () from te clamp (3). efor leaing, remove the alr leaner, NOVING THE AIR CLEANER), Witz the dain tube (1) from te lamp 3). Ferme the pug (8 Empty te oto Some kind of eons, ard bot nal and at trough hose (7) ‘he thermal switch (8) oe rate energizes anc ‘ches on the elaine fan (9) the coolant tempera. {ute exceeds 95°C (202 ‘nen thea a over th actor bythe an rouoes te oslant epernie ln B80 (Y04) the eva ‘wish ume te elect ano “The incase in volume cased byte heating ofthe ls 's compensated forint expansin tank 10). The racer brouher te (1) comect the aaron an iS fnCooling system [Scarabeo 150 REMOVING THE RADIATOR esd carefully COOLANT and PRECAUTIONS AND GENERAL INFORMATION, Dain ofthe coor compitely (sea CHANGING ‘THe COOLANT, Femove te inne tot shied (s8e REMOVING “HE INNER FRONT SHIELD). Fmeve he tloer pare! ower guard (REMOVING ‘THEFLOOA PANEL LOWER GUARD) Fmeve the octets (REMOVING THE FOOT: Resn Fomove the tune {REMOVING THE TUNNEL) Disconnect he mo elactical connectors (1) and (2) trom he tetra sc (3 NOTE obtain new soenciversype hose camps to replace tho ol carpe epoca cross type), (Cathe camps (4) ana) NOTE Aways use new clamps (f) an (5) wher rating. Disconnect the wo hoses (6) and (7) from the raior Cut tha head of he hose clam NOTE Use a now clamp (6) wren iting scannect the brea D0 (9) om fs connect on ncrow and remove he tre serows (10) (There a wo lateral screws, one on each). Lite radiator up out fs mounting pn holes. “caution. Proceed with care. Do not damage the radatr fins. Fereve the radiator (1) ina downward ection, REMOVING THE ELECTRIC COOLING FAN ead carefully COOLANT and PRECAUTIONS AND (GENERAL INFORMATION Remove the inne ont held (668 REMOVING THE INNER FRONT SHIELD), Remove the foavests (REMOVING THE FOOT: REST Remove the tunnel (REMOVING THE TUNNEL}, Disconnect ne seca connection 1) one fan Boloase 00 2001.05Looeen and remove the to bots (2) (ne fom the cer side), Keeping the ruts. Lower the elect fan (3) of ts support. Remove te elec lan na dowmvard oxon, oaing rom te op 9. NOTE win refting the fan tt tthe top pin ist ‘and hen to te suppor plate tthe bottom. REMOVING THE COOLANT THERMAL SWITCH Resd carefully COOLANT and PRECAUTIONS AND (GENERAL INFORMATION, Postion he motorjco on be care tan “Awannons. ‘Stop the engine and wait unl the radator cools ‘coun, Femave the inner ont sil see REMOVING THE INNER FRONT SHIELD), Disconnetthe to elactcal inal (1) 2° (2). Avan DO.NOT DISPOSE OF COOLANT IN THE ENVI- RONMENT. ‘hen you unscrew and remove the thermal switch {@)a certain amount of coolant wil come out of ts ‘mounting hoe Puta container of approximate capacity 1 erin postion to catch the coolant as iteomes out. Peation an absorbent cioth atthe bottom ofthe radiator to eateh any coolant that spills out LUncrew and remove the thera aie (2), ang wth he seal washer. ‘AcauTION When reiting, apply LOCTITE © to the thermal ‘switch thread (3) 2001.05,Cooling system ‘Scarabeo 150 REMOVING ‘THE COOLANT THERMISTOR ‘ead carfully COOLANT and PRECAUTIONS AND (GENERAL INFORMATION. Drain ofthe coolant completely (S00 CHANGING THE COOLANT Remove he comer inspection cover (se REMOVING THE CENTRAL INSPECTION COVER) Disconnect ne slsctren connector () UUnecem and remove the themisor (2 ‘Thermistr tightening torque 158m (1.5 ge) (11.1 Fes AcauTion ‘When refting, apply LOCTITE © to tho thrmstor threads (2) REMOVING THE EXPANSION TANK ‘Read carefully COOLANT and PRECAUTIONS AND GENERAL INFORMATION. Poation ie motreyete on the canter sana Remove the inna font hil 06 REMOVING ‘THE INNER FRONT SHIELD), “awarnine DISPOSE OF COOLANT PROPERLY. DO NOT DISPOSE OF ITIN THE ENVIRONMENT. USE A SYRINGE AND TUBE TO SUCK THE FLUID (OUT OF THE EXPANSION TANK, When the hose (tis disconnected, the cootant contained inthe expansion tank (2) il ru Puta container of approximate capecty 1 it position to catch the ud as it comes out Place an absorbent cloth under the expansion tank to cateh any coolant that spils out NOTE obtain scrowctivertype tose clamps to ‘eplace the agin special screws yp. ch. 5 Bolease 00 2001.05Cooling system, Scarabeo 150_| at the clam (ot. Disconreet the hos (4) tom ts comnactor onthe fxpangion tank, Cut the head othe clap (3). ‘isconnoct the hodo (1) om hs caret an he ‘Gicky place the container under the exparsion ark ‘Beatch he coolant “Awannin Coolants harmful Keop the container ina safe plac. KEEP OUT OF REACH OF CHILDREN Unscrew an remove ho sore (6). Rerrove the expansion ak 2). ‘THERMOSTAT VALVE Frinton onthe thermestat valve, sae ENGINE WORKSHOP MANUAL 91000 (-0), 1001 (LUISA) snd 1002 (FE), COOLANT PUMP. Forinfomation on he coolant pump, see ENGINE WORKSHOP WANUAL 91096 (-D},n°1001(LUSA) fans n1002 (F), Foloase 00 2£01-05 ch.5.Electrical system [ Scarabeo 150 Electrical system Bolaase 09 2001.05lectrical systom BULBS ead carefully MAINTENANCE, Avanwne ‘The vehicle must not be used ifthe ight ae not functioning properly. ‘Thevehice must not be used if the heaclight is adjusted incorrectly. This could temporarily bing ‘oncoming car, and also reduce the ier's ality te see any obstacto along the road while riding at ight. Wis always advisable o reduce speed when riaing ‘during the night, such a way ato have the me ‘necessary to avold any obstacle and to adapt to the poorer visibly that inevitably results trom ‘arineas, Failure fo observe this warning can lod {oacolision with another objec, with consequent tsk of serious Injury or even death Awannnia Fisk offre Keop fel and other flammable substances away {rom the lecvical components. Before changing a bulb, tum the ignition switch (A) tothe "2" (OFF) poston and walt a Tow min ‘es co that the bulb cools down. ‘Change the bull wearing clean gloves or using @ clean and dry cloth Do not eave fingerprints onthe bulb, since these ‘may cause ts overheating and consequent break: ‘You touch the bulb with your bare fingers, re ‘move any fingorprints with alcohol in order to veld any damage. ‘TAKE CARE TO AVOID DAMAGING THE ELECTRIC CABLES, NOTE betore changing a bul, chock th uses, ‘CHANGING FUSES), ‘CHANGING THE FRONT AND REAR DIRECTION INDICATOR BULBS Read carefully BULBS. NOTE Betore changing a bulb, check th uses, (s88 ‘CHANGING FUSES). “To change the bulb NOTE Tho fotowing intormation retest one rec tion ineeator only, tis val ral of hem Piaceth vehi on tha cant eand, ose PLACING THE VEHICLE ON THE STAND), Unsere an emove the sere (1), lease 00 2601-05 ‘Scarabeo 160 STOP and WAIT!ical sys ‘Scarabeo 150 Acaumion ‘Upon reassembly tighten the serew () moderately and with eae to aveld damaging the lens ane the Colored sereen. NOTE wie removing tr lens, use exra caro be sure that you do ot oreak te kay. Fomve tho los (2). NOTE Upon reassemaly place ho ons cect in Femove the colored screen (2) NOTE Upon reassembly place the colored serean cont nits sot sh the Bub (i ight and eat Wt counterdook Eract he Eb from i st NOTE Ince the bubin the bub socket. careuly aligning the te bub pin wit thir gues inthe ‘Cente ital a now bub ofthe same ype. NOTE Upon reassombi tthe bul coke 5) has fain out fs seat, replace iteorecy, ensuring that the stint reflector ais wi the Stew hon the body of te wn signal amp, CHANGING THE HEADLIGHT BULBS. Read carefully BULBS. NOTE fefore changing abub, check he uses (see (CHANGING FUSES) ‘he headlight contains ne ah beara halogen bub 1) canal pon. one pang ight bu (2) (cota lmer poston) ‘TO.GAIN ACCESS TO THE BULBS Uso ane remove tho ere NOTE Do rot mx screws. Upon reassamby, take care nario invert the poston o he sew () ote sen (3). Unscrew and remove the to sores (3). move tha ame (5). strat te reteto (8) NOTE Upon reassory, instal rece (6) sorry making he iaaron coats cane wih the ‘AcauTion ctr (6), inorder to prevent from aceldentaly ang down. To change the bulbs: orang, tom te conval rors pat of he vehi, and ‘operating onthe roar par of thereto (3), Belease 00‘Scarabeo 150 (CentRat Postion) ‘Acaurion ‘To extract the bulb electric connector, donot pall, is electne wire. Grasp the bulb elcrc connector (7), pul and ‘Seconeet trom the bu (+ Rotate bul sockot (8) counterclockwise ano ‘ara from terete Femove he bu (1) tom the soa NOTE 22 sure to maintain he same cranntion at ‘he od bu when you inal the new bub Do ty to roe the bub, I wil go easly s propery overtes. Inset he new bu (1) let the eter, by aligning ‘he wo tabs (8 onthe bub wih the respecive gues (10}in tne reflector: Postion the bub socket (2) inthe refetor and rotate ‘locks Connect te bu eletre connect (7) Fepace the loca (8), 00 TO GAIN ACCESS TO ‘THE BULBS) PARKING LIGHT BULB (CENTRAL LOWER POSTON) ‘Acaumion “nile removing a bulb cocket, donot pull on the Grasp tne bu socket (1), pull and remove rom Femove the parking ght bub (2) anc replace t with eneentcaltae tet NOTE Ensure that he bul is conectirseied in the bulb socket Inset the bu socket (11) in ts sat pace the toca), soe TO GAIN ACOESS TO CHANGING THE REAR LIGHT BULBS Read caretlly (BULBS). ‘Awarnina Do not ride this vehicle ithe tai ght and the ‘stoplight are not working propery ‘Tho stopight is parculaly important to prevent ther vehicles from rearending you, Obviously, {aire to comply with these instructions could Tead to serious accident with subsequent injuries ‘or even death NOTE Belore changing abut, check the tses, coe (CHANGING FUSES), also check the operation ol ho ‘Stoplight suthes, 068 CHECKING THE SWITCHES) Bolease 00 2001.05.Electrical system ‘Scarabeo 150 Treo at conti: he psig ight spit (1) onal exit) “re eee pe ut ta on poste). To Ga access To THE BULaS Pace he wei one cert tar see PLACING She VENGLE oN The STAN). Unsce andremore he wo sre omovies) [NOTE Upon eascony, make su that holes Seats prepay. ‘Acaunon ‘pon reassemaly, dona overghen the wo Gower) Overtahering wil eek he one ‘To change the but: PARKING LIGHTSTOPLIGHT BULB {CENTRAL POSITION) eo remove the parking lgrstopligt bub (1), push the ‘ub sight fond snd otatet countrlocse Pultton ts seat ‘Corey intl a naw but of te same ype NOTE censure tat he orontaon of you: ropa: ‘net bulb sre otal ote rg a. Do rot oto fore he bub, wl easy is propery Stetes. Replace the lens (4, (60 TO GAIN ACCESS TO THE BULBS) LICENSE PLATE BULB. (CENTRAL LOWER POSITION) Remove the esse pat bulb (2) an replace it with an nial but, NOTE Ensure thatthe bub is comecy inserted its ‘Replace the lens), (s¢@ TO GAIN ACCESS TO THE BULBS), apriiaElectrical system, ‘Scarabeo 150 CHANGING THE DASHBOARD BULBS ead caretlly CHANGING BULBS, Cn the eashboud hae ar ‘he warring light, the dashboard ights andthe dock Dbatory (CHANGING THE CLOOK BATTERY} follows: Femavethe headlight support (se REMOVING THE HEADLIGHT SUPPORT), the bulbs and battery, proceed as Wrsing ight bulbs Femave be bl let forthe bu that neds tbe change oT ven 1 Liste [aan Tag geo Fave te bu and loo th abub ote same te Dashboard it Remove the bulb oir corespenng tothe pooty lurinated part othe dastboard Pos. Tina one Femove the bub and replace it wth a bub ofthe same Np. (CHANGING THE CLOCK BATTERY Remove the headlight support (see REMOVING 2 4 ‘THE HEADLIGHT SUPPORT). Se Fre te clock suport (ton the back othe ds a eae board by releasing he eatch (2). “ake out the cock and change te baton.‘Scarabeo 150 Electrical system. ADJUSTING THE HEADLIGHT BEAM VERTICALLY warn 'Do not use the vehicle te lights are not ure- tioning property. Do nat Use the whic the healigh is adjusted Incorrectly. This eould temporary Bnd oneaming iz reduoe the ier’ ability to see any ng the road wile riding 3 ight. itis always advisable to reduce speed when ding ‘during the night, m sucha way a5 fo have tha ime hocoseary to avald any obstacle and to adaptto {the poorer visibly that inevitably results rom ‘arlinoss. Failure to observe this warning car ‘use you o coli with anothor objec, with ‘consequent risk of serious injury or even death, NOTE the prosecure described hare iin com- ‘ce withthe allan candard tat exabiahos the maximum height of te heacigt bean. For vonies used is thor counties, you must cen format tne eel reguations somes) ‘To qui check he core adjustment of he bean, Bice nie on ft pour, 10m 2 ay ‘Tu on the lw beam, ston the vehicle and make Sure athe beam projected on he wal sgt Ur the horzrral ts othe headlight abot 2100 ofthe total hag ‘To adjust he heslight beam vertically: ‘AcauTion Do not force the serew beyond its limits. ‘Adjust th srow (1) wits abont box wrench (2). Turn the scrw clockwise o adjust the beam niger (epwaras) ‘Trmthe sorew countrlockwie o aust the beam lowoe(downears) Awanwna ‘Make sure thatthe vertical adjustment ofthe ‘ealight beam is coro awannona: Hake sure that the horizontal adjustment of he adlight beam fs correct, (soe ADJUSTING THE HEADLIGHT BEAN HORIZONTALLY). Boleace 00 2001-05Electrical system Sei ADJUSTING THE HEADLIGHT BEAM HORIZONTALLY AA WARMING Do not use the vehicle the lights are not functon- propery Bo nat ue the velco tthe headlight Gjustod incorect. This could temporary bine ‘oncoming care, and ago redies the riders ait) > Seo any obstacie along he oad while ring at, Fight Ie always advitable fo reduce spoed when Fang curing the night, n such s way auto nave the time necessary to avoid any obstacle and to adapt to tho poorer silly that mewtaby reulls trom Sorkness. Failure to obervo thi warming can eaus> outa colide with another abject with consequent Fisk serious Injury or even death. NOTE The terms ght" andi ao otonedto the "ier seated on he vere nthe nema riing postion Fig poste to alt the horzora positon bah 1 he ight a tothe et ‘To aust the headlight beam orzontally: “A.caUTION ‘Do not completely unscrew nor remove the serews (0) ana Looson he serews (1) and 2) ‘Once screws (1) anc (2) ae oso, you may agust tho beam tothe let and ras you wis, Proceed ver) eta as foto ‘AcauTION Do not force the sides of headlights beyond thelr Tits ‘To asust ine beam tothe right, apply force as ‘own in igure Push onthe ight oof the headlight 2) and pln ‘hele ae a he head ‘To adust the beam tothe et, apply force as shown igure 8 Push on he let side of tha heaaoh (5) and pl on ‘he ight seo! he alight). Winer you are sailed wh he oust, hen ‘he sews snugly. Donat overightan. AccauTiON Tighten the screws (1) and (2) with cae. Awarnns ake sure thatthe horizontal adjustment ofthe headlight beam ls correct. Aware ‘Mako sure that the vertical adjustment ofthe headlight beam ls correct, (eve ADJUSTING THE HEADLIGHT BEAM VERTICALLY). 2001-05Electrical system Scarabeo 150 CHANGING FUSES Fac carefully MAINTENANCE. “AWaRNING Fisk offre. Keep fue and other flammable b= ince nay om ns cca componente repair faulty tases, Use ony recommended fx AcauToN Using uses of an improper capacity can cause {damage to the sleotrcalsyotom ora slecrcl re, ‘onion sould result in total Gestructon of his vonicle se wal asin yo, Haute blow requenty tere probed ea short ‘eur or an oaroad int ocica speen an scene ‘component Ses net werk or wots regu of Fe ‘ec also star, tis necosary to chock th es ‘TO GAIN ACCESS TO THE FUSES: Remove te front over, (6@ REMOVING THE FRONT COVER}, Fuse ciRcuT ‘This vehicle's equipped wah tre fuses: 78 Afuse (1. From tigation ete ogriton oats From the ignition switch ol igh ads a hon. 20.Atuse From eat toto atch, vtage rgutr To CHECK THE FUSES Tum he ignton swich (4 in the (OFF) poston NOTE Thea fuses are spare ure. ‘AcauTION Extract ho fuses one by one, sucha way as 0 voi replacing them icomecty during resasembly. Remove, oe by one, he tse aedinspect te mart (5) tl open th use must be roplaced, place ho blown uso withthe appropriate spars fuse or wth anew fase having the same amperage rang Awantens you replace the fuse and it blows again immed sy, there isa serious problem with the electrical System ofthis vehicle: Do not atempt to contnue sing this vehicle [NOTE check he spare fuse hole. the appre ‘a spare tases are not here, epics ther Bolease 00 2001.05Elgctrical system ‘Searabeo 160 WIRING DIAGRAM olease 00 2001-05Electrical system ‘Scarabeo 150 WIRING DIAGRAM KEY 1) Gonsratoe 2 gation cat 5) Sarer motor 7) Staring lay 8) Beato light font witch 9) Beak ight oa sue 10) tar temperatura thermistor 11) Engel pressure sensor 12) Fig crectonnseatore warring ght 18) Fusl sensor 18) ear docton nator 15) Tag 46} Rear? erection indicator 7} Flasher 8 Ignition key sch 18} Fight hghow beam soictor 20) Lathighiow beam selector 21) Complete dashooara 22) Low beam wang ight 25) Dasnboaa ights 27) Water temperature gauge 28) High beam warig lt ) Let direson ndcators warning ght 30) Hom 231) Front ight rection inscator £2) Lowhigh bear ihe ) Fron park ight 28) Front deeconincoator £35) Engne all pressure warning ight 236) Mulile comocors 37) Spark pig 38) Automate tener 39) Head 40) Foo everest 41) Fan 42) CDloonrolunt 45) Thermo suten 48) Pokup 45) Usonse plate ight 48) Thermometic sch STARTER, anere ‘WIRE COLORS Br orange Be ght oe Bue Bi white @yelow Gr gay Moun N Bloc Ro res v reen ve bute Fo pik Belease 00 2001Electrical system, (CHECKING THE RECHARGE SYSTEM Retr tothe folowing hey when consuting ten estos fe Lpetbiue & bus i Bron is 4B (CHECKING THE RECHARGE VOLTAGE ‘check ne electron tovel(see CHECKING THE (heck he battery volteg (00 F BATTERY). Psion ho motoryce on the center stand ‘State engine are tke 19 2000 rpm (hota ental ened appreciate rene), Sich tho ight woh fo ">" polvon ar falecorto te “poston. Using a ponabe tester chock the contruous votage bench ata pone (9) endneate Ihe tata reasng i ss than 19 V or greater han 15%, Chak the funeson an contrty of the aerator ‘without ted, (CHECKING THE ALTERNATOR WITH ‘OUTLOAD) aed (CHECKING THE ALTERNATOR CONTINUITY) and he votage regulator (908 VOLT: GE REGULATOR} Key to second figure 1) otage ragdater 2) atiery 5} lion switen ruse ‘Standard charge voltage: 181015 a.) ot 3000 pm. HARGING THE ight (CHECKING THE ALTERNATOR \WiTHOUT LOAD Remove te ton tik Datanneet the regis wre connect: (1). ‘Stath engine ae take 10 S000 rpm (ote onal umed spproxatay 16 of ange) Fost the maforeyele on te conte ta, Using a portable tse, et he vtoge ‘nt 0) betwoan nets yllon wires (, The tstrreaing i oss than 4S V the aerator is oletve ‘Standard voltage without load: greater than 5 V {ae} a¢3000 rpm, lease 00 2001.05 ‘Scarabeo 160Electrical system ‘Scarabeo 150 (CHECKING THE ALTERNATOR CONTINUITY . ‘wnt the engine of: Remove the rot shies Discennec the regu: wires connector (1). Using & prio tester, ost the contnuy between the yolw vires (6) of th star. ‘iso, chook ne soon a the stator surge ‘Standard resiatance: 01-10 ‘Slandardreslstance between wires and sta ‘supports Git VOLTAGE REGULATOR Remve the toot shi. Disconnect the connector (2, ‘Unscraw ad remove the screws (2) and dsconrset the terminal of wire () and ie (5) Acaumon, nen reassembling, reconnect bth wires) ane (6) {Using vai tio fraieE0) fat ea e Fegulto ia) tha reicance betwen the wires Indes inte tabla ben Ih restance reosing is incorrect, change the regulator. Taso postive emainal e[a[e[ale lav ite [-[-[-[- = Elwl-[-|-|-|l= NOTE This inssecton method onl apraxia possible, subsite avokage repute st you ow won, lo check the caging cu ch.6 Release 00 2007.05‘Scarabeo 150 IGNITION SYSTEM WIRING blaGRaM 1) Baty 2) CDI. contotunt 3) Pickup 4) Heat 5) To susan services 8) Sparkpiug cap 2). Votage regulator ‘erator Spake pig £0) Igrton swe 5) Stopistant 12) Engine stop switch 13) To cabureoe heater system CHECKING THE HT CoML Remove tel sdeinspacton cover (s88 REMOV: ING THE LEFT INSPECTION COVER), Disconnect the termina (). Disconneat the spark ug cao rom the lead. Take readings (A) and (B) shown in the igure, using a potable ester. 2101.05trical system Koy to figure Ay Measurement 1 Bi), Measurement 2 12) Tabs 13) Bosstance te 18) Black HT eas 15) How Standard readings: Moasutomen 1705 +25 Measurement 2! 135k # 20% ‘Scarabeo 150 “AccauTion ‘The measurement method ie only sppraximat. It you gan, sett co that you know abe Boo. CHECKING THE PICK-UP With the engine of: Discennoe he eaecr (1) and ke the reatras {on the picup wies tein. ting prtabi asta (scale 1000), measur the reetance betwoen the Buniyatow (8G) wie ard (qeennite (OB) wire terminals, Standard reacing: 2400 DBasconnoet tno connor (sing ster test he roitane beswoen the te allo he ahoel side ard the engine ack: Standard reading: 00 ithe resstance reaig isin or less than the Salo value, the pick mse be replacs (CHECKING THE ¢.04, CONTROL UNIT Remove the rot she Disconnect the elects connector () from tha 6. ‘ont ut Connect the postive {+} and ragatve ()teminas of { porabo tester to al eternal oo the C.D ‘onto a (3), checking the contuly and messing the resistance, the contruty an rxstance exdgs correspcns to ‘he values shown In fhe table bec, be O.Di- carol unt is probaby goca “eet be raitance Between he terminal, a ehwwn, oh. 6. Biolease 00 2001-05trical system ‘Scarabeo 150 ‘Acaumion Foe a {As there are diodes, condensers and other eloc- ‘tonic components inside the C.D. control unt, ‘the mesturement method deeeribed here ie only approximate inorder to make a more detiniive check, either replace the contol unit with ne that you are sure Is good, or cary out the chocks described In ‘CHECKING THE ELECTRICAL SYSTEM FROM THE | DL. CONTROL UNIT CONNECTOR. (CHECKING THE ELECTRICAL SYSTEM FROM THE ‘EDI. CONTHOL UNIT CONNECTOR Remove the front hits Disconsc the electrical connector (1) from te C.D ‘onto unt Using 2 prado tester on the etecical connector (1), ‘ake the reacigscescibed nthe abe, 2). Pelcup ornina (yellowioray wie (G1). 2 3 4 '3) 7.5 us torminal (roteacx wie (FIN), 4) HT coltrminal(whelpurple wre iN). 1 5} Ground terminal (ive wie (3) 1) Fie! round trial esneitack we (GN), 1) Pic-upterminal(ellwbive wire (6) 7 6 ‘s ‘pilion aed Tending out of ange ee scone pee ator | "heer folowing eben ardbteyaw BS 3S ine ta)_| 08 aap wing isa (8) an erga end @ ainsio [oot a elbwtiad (GR ang erga pang o eines | 0-1 ag [nieve Gi) ad eine ge e ormeiay | 0-2 col wi shee (BU) ard eae one) &. ns (0) | iy wig {col pian scone) ae TA a aT we | eT wae (exotieom somata, ses avin (GPG) and aie end o ‘se a_| iy Poo Ite values ae cooet anda malluneion esos, thonthe C.D. convo uni is dtiay deocive and must be replace. (7 This readeg must show the bat votage Bolease 00 2601-05 s ||Electrical system, _ ‘Scarabeo 150 COOLANT TEMPERATURE GAUGE ‘wrina biacRam Wiring tagram key 41) Coolant temperature gauge 2) Termistor 5) dattery 2) etn sites 5} votagerequitor 5) tolgiion Remove the rear ang athe a box Disconnect ominal (7) (whee wre (8) am the thor, CConnot a 25 W rsstor (to ermal (7) “urn theigiton etch fo posson ">: ‘Chock tat the point (8) goes fo the start of the rod one (Max’} wn a oleranoe or 5 ch. 6 Bolease 00 2001-05trical system, ‘Scarabeo 150 CHECKING THE CONDITION OF THE ‘THERMISTOR Frrave the thrmister (1), (600 REMOVING THE COOLANT THEAMISTOR}. De inatrated nthe Hour, Sonnac a pocket ester 2) (Getto chmmater meas) othe thermo (1), Inmeree the hermstor oa recoptace (9 containing Imgrse a thomameto (4) wih a range of 0°10 ‘80°C a" to 902") the same receptacle Postion te rosepace over a burner (3 an Slowly Feat bqus Check ho Tomperature reading on the thermometer fa the thomistrresing onthe teste ‘heck tat ho themistor responds fo the temperate Ss Shown balan ‘Coolant temperature | _ Standard values scr) Tay 50" (122 = 226260 15230") 26810 the values do not change, or Hf tey fe too ‘uch irom those Inthe table, replace the there mstor with a new one 2001-05 ch. 6Electrical syst ‘Scarabeo 150 ELECTRIC COOLING FAN PS eum ‘WIRING DIAGRAM Wiring eagram key 1) Beet fan 2) Thermal swach 5) battery 9) Main tuse 5) to votage requir 8) toigniton swics ‘CHECKING THE CONDITION OF THE ELECTRIC FAN To check the werking state othe fan (1), precoed as ‘oto: Femeve the oe pane Disconnect wo aleticl terminal (9) are (4) am ‘ha thermal switch (2) and connec: them upiogober. Ite lan doesnt rn Chock thatthe connacor (8) i lugged in propor. “Tune tan marwaly and choc ta he bids 0 rottouch the suppor, Ite fan rotates rea Chock th recharging systom (se CHECKING THE RECHARGE SYSTEK andthe maintuse (coe ‘CHANGING FUSES), chElectrical system Scarabeo 150 CHECKING THE CONDITION OF THE ‘THERMAL SWITCH Remove the tear pane Ferave the tharal sth (1) (600 REMOVING THE ‘COOLANT THERMAL SWITCH) ‘As iustatedin be Ture, connect a portable ester £2) (cto shmmotr mos) tothe ermal seth (1), Irmors the thermal swish in ecepace (3) con taining coolant. Inmere atermemotr (4) wih a range of 0 to 130-6 (2 fo 02°F) inte sae receptacle, Poston he rooptade over a bumer (8) ard souly feat the qu. Choa thal he tomporaturacoang on th thermo ‘ran the tharmal stich rea onto testa arespont he data inte abe ‘Standard values ret toes than 96° (194°) aie than 100" (22 the values die om those shown a he abo, change the tema Soh FUELLEVEL CIRCUIT ‘Win DIAGRAM ot A ge it sv ] Jace ¥ ‘ 7 1) Foal level nator Foal oel sensor Battery ) ignition owen Fuel recorve warring ft (yellow amber coor to volage regulator "onion ston Beloase 00 2001.05.FUELLEVEL INDICATOR roar feig. Disconnect the way connector (8) rom the ul senea() checking the pot Connect 10 resistor othe gray/groen (GV) and ue () wes of connector (8) (ig ice). ‘Chock tat he pointer (8) goes to, wy a tokrance ons. Fepeat the operation using @ 902 resistor and chock that ne potas () goes 2 (2c) wih a leraroe of 25 (Checking the fuel reserve waring ight Make a det conecion (eistance 0) betwean ‘he erangetlack (APN) ar bus (8) wires on conse (8) (wring side); cack ha th ua reserve ware ing igh ighs up. ‘ring etagram key 8) Sway comnoctr 8) Poiner 4) Ful reserve warring ight 11) Fosllevel nator ch.6. Scarabeo: Boloase 00 2905-05 m= Ss ‘wi Sere ‘reading apse] ga) ae | wa |e saroeeae aT — coe alFUEL LEVEL SENSOR ‘Checking the condition move ne rear aig. Disconnect tne 3tay connecter (1) onthe fuel level sensor Using 2 portable tester (3) (eto ohmster mode) on the connect (1) (eansor ee: ‘Connect up the graygreen (GV) are bio (8) wires and check that the readings match te tale vats in the wo sensor postion (ert! and upide down CConnact up the orangatak (WN) arabe () wes land oheck hate readings match the tale vats In the wo sensor postions (erica! and upside-down Been wires] Sencor postion sevgeen S| verroa, | ania 00a oa : cergee i] ursmccom | 41008 Soni) wamgebie RT| aaron Maceo) RTCA. oe cpeec| ursocoom | =a CHECKING THE AUTOMATIC CHOKE (COLD START) Remove the airbox Disconnect the cortaspondingelctical cnnoctr. Remove the automatic choke (2) rom the carburet: {see DISASSEMBLING THE CARBURETOR). ‘Wil unl he choke gets to ambien! iemperatire (10° to 25°00"t0 777) Power up he choke with 12.V do ‘or thee mites, check hat the pointe (2) has snowed Tovar at eae 9 en (0.1 ‘Checking the circuit “This tastcan be dono in two ways ihr: ‘th me engine of using a special mutstr wih tn engine king (1600 ep), checking that there i voltage athe terminals of connector () (rout $id) (tne cet working propery 2 {0 W bub shou ght) _on.6 EE 2 00lectrical syst ‘SWITCHES, Using a portale stor, chack te continuity of te ‘Siches and eter tothe spot able or each SWE Replace te swtch is aut. 1) HORN BUTTON.) nae ae ~ | oo 2) HIGHILOW BEAM SELECTOR (=) EN [en [wn | or] #5} O-[-O oe OFS 2) DIRECTION INDICATOR SWITCH (<.) 6) 1GNITION BUTTON Tew | Ree 3 oto 7 IGNITION SWITCH eae |] EGE) on. Roloaso00___2001.056) BRAKE LIGHT FRONT SWITCH Beer | viG on | OO 9) BRAKE LIGHT REAR SWITCH Tw Rar | vie on | O--0 ‘CARBURETOR HEATER WIRING DIAGRAM Wiring diagram key 4) tigation creut 2) asta creat 53) Thermal sich Heater 3) Batery 6) anion swecn CHECKING THE HEATER Using a tstrin ommeter mod resistance ate termina’. Correct ue: Sto 180 at 25°C (7F) Belease 00 ch.6 arabeElectrical system ‘Scarabeo 150 (CHECKING THE THERMAL SWITCH Using a tester in ohrmeter mode, tat the oon ty oft thermal switch acevo tomperatces, Less than 3:0 (87.4) Creator than 16° (60°F) comes vse 02 (CHECKING THE PRESSURE SENSOR ‘Tocheck the concn of he sensor, proceed a folows: Take of the ser cover (1) Clsconnect he slcrca terminal rom the senso: 2). Using aster (cala x 1000), check ha cranuiy ‘etwaen the tab trial (3) andthe sensor bod. ‘Correct value with engine off: 002 Correct value with engine running: © ite reatings donot corespond to the tated values, ‘heok the engine level an replace the sensor with ‘Sew oe, Icessary. Belease 00 2001.05Electrical system, STARTER CIRCUIT Location of components (s8e LOCATION OF COM: PONENTS} wing eageam hoy 2 Set mat 3) Sener 5), Bras ight ron swicn 10) Brae ig roar ston 18) lon anton 15) rao igh 38) StnerButon portant: For safety reasons, the engine wil start with the "button only when one of the two brake levers 's pulled ‘TROUBLESHOOTING |. STARTER MOTOR DOESN'T TURN (Oheck the battery (CHECKING THE BATTERY), Check the 7.9 use (Check the starter tor wring connsctons (heck the starter ay (CHECKING THE STARTER RELAY). (Check te stanor buton "(CHECKING THE STARTER BUTTON, {Check he brake ght atch (CHECKING THE BRAKE LIGHT SWITCHES), 3 pelea co 200108 crs ||Electrical syst ‘Scarabeo 150 1. STARTER MOTOR TURNS BUT ENGINE DOESN'T TURN OVER, Check he starter mato, the sorag ech and the spragctch goat (C.STARTER MOTOR TURNS BY ITSELF, WITHOUT PRESSING THE BUTTON (Chock tho starter mote wring conection. (Chock ho stator olay (CHECKING THE STARTER, RELAY}. INSPECTION DATA (CHECKING THE STARTER RELAY ‘isco al the wires rom hor (1) Using str in omer mod, est be contnty botwoon te power trmina (MS sroH), Coste value nin Power up the power contacts connector witha 12V bate. ‘sing tester in otmmetr mage, test the continaty batween the power trminas. Cored vaio: 0. (CHECKING THE STARTER MOTOR Disconnect the spark lug exp, seh te ignition ‘ute fo ON and start up math he ammeter conrectod tothe saner motor era. Normal values 8 A 15 at anning speed ‘Using astern obmmetr mado, est be resistance between the pocibve and negative ternal of re Sater moto: Normal valu 0.210%. (CHECKING THE STARTER BUTTON ‘connect he burton coat. Using a eso in ometor moc, tst the contr ‘twton the contacts nthe preseod an ost ps tions by testing the connactions (MAIN HIRING. DIAGRAM coi |e oease 00 2004.05Scarabeo 160 TURN SIGNAL CIRCUIT Locson of conponenss08 LOCATION OF CO PONENTS) vnc DIAGRAM ; A eae az R 2 I % BH @@ WW ai] 4] aq) 2a) w6 e's a". ostve VR | [BN 3 = eyconotee 14) Fight eartu signa 40) Leltreartum signa 18) Turn sgnal elector 22) Paver 24) Loft tam signa warring ight 50) Right wn ional warning bt 831) Fron aight wm signal 2) Frontiot um signal TROUBLESHOOTING A.InbIcaToRs DON'T WORK Chock the buts (Chock th um sina wing connections (Check the un signal selector ‘Check the genera power supply excl Fopiaos th fash '. INDICATORS STAY LIT PERMANENTLY WITH: OUT FLASHING. (Oneck the bub specfeatons. (Chock th eattry (CHECKING THE BATTERY), piace the facet. Ficlease 00 201-05 (eeeElectrical system ‘Scarabeo 150 ‘CHECKING THE TURN SIGNAL SELECTOR Disconnect te elector connector Using ats in mater modo, test the conti between tne rs inne erent postions by testing tho conracions (ace MAIN WIRING WIRING DI GRAM HORN CIRCUIT Location of components (668 LOCATION OF COM: PONENTS), WIRING OVAGRAM Positive key-controlled 35) Hom 40) Hom bution ‘TECHNICAL DATA Hom rv 06. EE) cn lease 0 2001-05 BElectrical syst ‘TROUBLESHOOTING [A DOESNT SOUND, OR SOUNDS BADLY (Chock the batery (CHECKING THE BATTERY, (Check the Pom wtng connections. (Check the rem Button (CHECKING THE HORN euTTON), (Chock the hom (CHECKING THE HORN, '8. SouNDS conTINUOUSLY (Check the hom wtngcomectins. (Chock tha rom Button (CHECKING THE HORN BUTTON), IsPECTION DATA CHECKING THE HORN Disconnect the hom ang ten pomar't eat tom a 12 Vater. Replace Ft coose sour. ‘Aust the hor adusterifthe hom nes unsaistac. ‘ony. (CHECKING THE HORN BUTTON Disconnect tne buton connector. Using atestrin ammeter mode, est fhe contnty botwoon the contacts nthe pressed ard rot pos: ‘ions y ening the comnacions (WAIN WIRING DIAGRAM) ES Belgase 00 2001-05 ch.6 cotElectrical syster ‘Scarabeo 150 BRAKING LIGHTS CIRCUIT Lacan of components (ose LOCATION OF Cont PONENTS), WIRING DIAGRAM ; GI, start button Swen rap 9) Brake ight ron mitch 10) Brake ight roar evs 15) Talght BRAKE taht TROUBLESHOOTING |. BRAKE LIGHT STAYS LIT CONTINUOUSLY ‘Check hott connacons. (hecho brake lght for sich (CHECKING THE BRAKE LIGHT FRONT AND REAR SWITCH). (Check he rake ght rear such (CHECKING THE BRAKE LIGHT FRONT AND REAR SWITCH. B. BRAKE LIGHT DOESNT SWITCH ON ‘Choc ho bulb sn bul olde Cec he brake arcu wng connecons. (heck the general powor supply crea ‘Check he rake ton font awe (CHECKING 7 BRAKE LIGHT FRONT AND REAR SWITCH). ‘Check he brake gt rear swich (CHECKING TH BRAKE LIGHT FRONT AND REAR SWITCH. EEQG|! cnc _ Release 00 2001.05,Electrical system Scarabeo 150 INSPECTION DATA (CHECKING THE BRAKE LIGHT FRONT AND REAR SWITCH Cisconnact he etch wire: (Operate the brako an test the esstance between the 2 sich emia, using tester ia ohmometer Normal valve with brake engages: 02. ermal al wth Sree not engeped: infin. UGHT CIRCUIT Location of components (S86 LOCATION OF COM. PONENTS), WIRING DIAGRAM tgnition switen Aen g54, 1) Roar paring ight 2) Fight highiow Beam slot: 5} Dastooata ight ‘3 Lowbeam warming Hohe Fron parking ight 6} Lowthigh boar ight 7) Uetthigiow bear selector {3} High beam wari ght 9} Loanse plate ght 00 2001.05, ch. 6trical system UGHT CIRCUIT m «> Lecation of components (S88 LOCATION OF COM PONENTS) WIRING DIAGRAM tonion swe <2 2 Y L 1) Roe patting ight 3) Dashboard ight 3) Low beam warning ght 5) Fron parking ight, 8) Cough oa gre 7) Lettnhow boa selector 8) High beam warning lake 9) Ueense late ight ‘TROUBLESHOOTING ‘A.A BULB DOESN'T WORK Check the bu, ‘Chock for votage on the bul ler terminals (Check the wring connections, NONE OF THE LIGHTS WORK. (Chock the Rit highow beam selectors EU" orion ‘Chock the 15 A use. ©. BULBS BURN OUT FREQUENTLY (Chock for excessive vibration om heights an check that rone of me lghs are wuching against partso! the motorayce without fenble causing. (Chock the wing connections. (Chock the votageragator {CHECKING THE VOLT [AGE REGULATOR. Beieass 00 2001-05,Electrical system Scarabeo 150 NOTE 2201.05 che |Ghassi ‘Searabeo 150 Chassis can ch.7 Release 00 2001-05,‘Scarabeo 150 Acaution ‘any of the bodywork components of his ve- ‘eles employ tangs and slot, as well astreaded {fasteners to retain them inploce Upon reassembly of any ofthese components, censure thatthe tangs ft coreetly inte the appro rate slots. ‘Aso, upon | ‘moderately. Be caretul not to ovetightn the screws. you do, ‘the component you sre alsching, as wel as the surrounding plas and painted components, wi be lroparably damaged, sscombly, tighton tho ser weonly ANTL-THEFT HOOK ‘The anfthet hook (1) is postions on the et seo the vehicle, near ho passenger foots. To prvent ih vehi rom bang stolen, te adie abl to secure i wit the apriia "ody Guard ar noted cab (2 Do not use the hook to it the vehicle or for any, purpose other than securing the vehicle onco has been parked. UNLOCKING / LOCKING THE SADDLE, OPERATION ‘To unlock the sade, proceed as follows: Page the vehi on tha centr sand, (se PLACING “THE VEHICLE ON THE STAND), Pace the ignition Key (5) the Ignition swichstering NOTE Tum the kay (8) without pressing it “Tame key (2) courtrlotnise (etwas) unl you aa the snap hatinseats thatthe cade lek spe “Tm ine key (9) back poston“ Lite sca (4), (se8 UNLOCKINGILOGKING THE ADDI [NOTE insrut yeu customers that betors towering ‘docking the ead (6 hey should make sure Nat thoy have Rot the grit key under he sade Tock the sade: Lower ara press wthoutexoring too much pes: sure), us making te sade lock snap shut ‘AcauTon ‘The vohiole should never be left unattended with- ‘oul the saddle being propery locked, Bslease 00 201-05Chassis ‘Scarabeo 150 SAFETY HELMET ‘Thanks othe soley hemel cas, you ne longer nave {bear the crash halmet er ote ject wit you ‘very bine you park the vehi “To reach the safety helmet case: Pace the case toy (}in he safely holmt case ock Tum ine case kay (9) courterlochuse etwas) Le ook unk (8) Lita epen the case cove (7). [NOTE The case can cortin one safety het: Two case keys ao supplied ogater wih fo etide (one spare kay NOTE rst our customer not keep he spe case ay wih hi veto, “A warnon “Te safety hlmet case must never bo overosded. NOTE Batre lenng ard ncing to ae coer Dir aye kt cae NOTE Wnon you nave loca he cas ovr, rove ‘recs oy) rom haste helmet ak ‘A.cauTion Do not eave this vehicle unattended without ensur- ing hatte eas cover (7) 1s property locked. Never earry any bags ot parcels fo the safety helmet ‘iso, a this may seriously compromise the ‘ranseuvrobty an the stay of te vehicle, REMOVING THE CENTRAL INSPECTION COVER ead carefully MAINTENANCE, ‘a wanton Before carving out the following operations, et ‘the engine and the exhaust silencer cool dows ‘unt they each room temperature. Failure to observe this warning mn ted to ser Place the vehlle onthe centr stand, (ee PLACING ‘THE VEHICLE ON THE STAND), nec ae remove tho sere (1), ‘AcauTion Proceed with cre. Do not damage the tangs andr tho slots in wich they tt Handle the plastic and painted components with care and avotd seraping or damaging therm. Remove the coral inspecton over 2). “A.cauTION Upon reassembly fit the tangs correctly inthe appropriate sots. Upon reassembly tghton tho serows only mad sly. Be careful not fo overtighion the screw {his will darnage the surounding plastic and painted components, ch.7. Release 00 2001REMOVING THE SADDLE ead earetlly MAINTENANCE. Awannna. Before carrying out the folowing operations, let the engine and the exhaust silencer cool down ‘ntl they reach room temperature Fallure fo observe thie waning can leadtogeri- us bur, Ferovete corral inspection cover, (sa@ FEMOV. ING THE CENTHAL INSPECTION COVER, Lite saci, (se8 UNLOCAINGILOGKING THE SADDLE}. Unsrow and romeave the seoms (1) ‘AccauTion Provood with ont. Do not damage the tangs andlor tho slots in which they ft Acauion andthe plate and painted components wih caret aveld seraping or damaging them. Pulte rear pans gery outward (Pes) (tt ard fh) ofthe contra fain (2. Ferove he cota fang (2) by witharawing it ‘onward (Pes. 6). ‘Acaurion Upon esssembly, it the tange correctly nthe appropiate sits Upon reassembly, tighton tho serows only moder- ally, Be careful not to overtighin the scrom, {his wil damage the surrounding plastic and Panted componente, olease 00 2001.05 ch.7Chassi Scarabeo 150 REMOVING THE SAFETY HELMET CASE Fed caretully MAINTENANCE. Poe the vec on the centr stand (ese PLACING. ‘THE VEHICLE ON THE STAND), Spon he saety name caze (1), (ene SAFETY HELMED, Take the holmet anor any oter object out ofthe case (1, ‘Accaumion ‘Unscrew and remove only the three nuts (2) and the tree serous (3) (nse the eras hole caso), Do not unserew any of the nuts and screws that ‘the pare! grid to the vehicle. Hold the three ruts (2), unscrew ad remove thettree serows (3) ‘Screw (tightening torque: 12m (12 kgm). etive the tes nals (2) and widow the thes spacer (4). Ge the safety hesmet cas (1), rae and emavel NOTE Tha nn rt spare (6) mt be wether from the parcel grid (6 by pling thom unwards wile the rear spacer (7) must be waherawn by paling dwar, Withdraw the wo front spacers (5 ard retive the washers (6), Withdraw the rear seace Maximum alowed weight: 3g (661 Ib). ‘Maximum allowed weight on the parcel grid (8): 9g (18.84 be) [NOTE Store the remaves components together ‘a safety helmet case (1) the tres nuts thothwoe Sees (2): thestvee spacers ‘eo Wont spac “ne ear sce (7) Inctéor be able to reassemble ham oowoety than yu rental the safety helmet case and washer ch.7 Beloase 00 2004.05Chassi ‘Scarabeo 150 REMOVING THE PARCEL GRID SUPPORT ead caretlly PRECAUTIONS ANO GENERAL INFORMATION. alee up th ead (UNLOCKINGILOCKING THE SADOLE} Remove the safety helmet case (REMOVING THE SAFETY HELMET CASE}. Loosen andremave he 6 screws ( “Tightening torque fr serows (1): 27 New 2.7 kgm) [19.9 Fes) “Take out te bushings rom tne parce gid support Remove the complete parcel gd suppor (2). REMOVING THE FUEL TANK COVER (SADDLE COMPARTMENT) Bead carey PRECAUTIONS AND GENERAL iirontaTiOn Fomave te seco! suppon rid (REMOVING THE FARBEL SoPROnr Ghig) ‘Remove the ead compartmart (REMOVING THE EABOLE COMPARTMENT) Ferove the sat eck (REMOVING THE SADDLE Bex Fmove the ar cloner (REMOVING THE AR LEANER {eaten an remove he 9 crows 1} ht secur the rearing {acre a remove the screws (3 anakeep the washers ‘itr the parol eather tbe (). caution Proceed with ca Do not damage the tbs andlor corresponding tab ‘lots Handle painted parts carefully, without seraping or Gomaging them Withdraw the complete sade compartment (5) 2001.05Chassis Scarabeo 150 REMOVING THE REAR FAIRING Fead carefully PRECAUTIONS AND GENERAL INFORMATION. Remove te sade compartment (REMOVING THE SADDLE COMPARYMENT) Disconnect he sacral coanecions (1), Remove the Scense pate Roker ard ine lense ate. Loosen and remove the screws (2) rome back Acaurion Proceed wih cre. Do not damage the tabs andlor corresponding tab Handle painted parts carefully without serapag or damaging them, Femove the compet ear ating (4) (long wit the aig rom me back REMOVING THE REAR ARCH ‘Read carefully PRECAUTIONS AND GENERAL INFORMATION. Remove thera aking (REMOVING THE REAF FAIRING), osen and remove the 2 screws (1). Flemove the compet rear arch 2 fom being GLOVE COMPARTMENT 1s poston st hana one inept Saeiner sh Sorc Facts ny). nae cena rea ay Soca Wa pao aoe caution Before eking he oo) ake sr tha youve sori lg Seta cSapioene ‘olock the door)" > NOTE Ws retecnsayo ta a tart Nona ty sin sowed wight 3.21 (15k EG! cz - Release 09Chassi Scarabeo 150 REMOVING THE INNER FRONT SHIELD ead carefully PRECAUTIONS AND GENERAL INFORMATION. Postion the motorcyce onthe canter stare NOTE These instractons must be eared tor th sides ofthe motoreyee Remove th fectret rat (1), (Open the glove comparmar: door (GLOVE COM. PARTMENT), Unsere and move he wo Bag-hook screws (2) Femowe the bg book (3). LUnerew and remove the sew Uncrew and remove he &eeoms (8), “caution Proceed with ear, Do not damage the tabs andor corresponding tb sot damaging them. ‘ witha ara move the inne ont hil, rotating owas the sade, REMOVING THE FRONT INSPECTION COVER, ead caretlly MAINTENANCE. (Open the glove companmer,(@ GLOVE COM. PARTMENT) LUncetew ar move the sew (1) Remove te ont inspection cover (2. AcauTion Upon reascambly fithe tangs correctly inthe appropriate slots. Upon reassembly tighten the screws only moder ely, Be careful nat to ovetghten the screws, {his wil damage the surrounding plastic and painted companents, 201.05 ch.7 |‘Scarabeo 150 REMOVING THE FRONT COVER esd carefully MAINTENANCE. Pace the voici on ths centr stand, see PLACING. ‘THE VEHICLE ON THE STAND}, Unseron and remove the seen (1). Acaunon Proceed with cre. Do not damage the tangs and! forthe slots in wich they th andl the plastic and painted compone {aro and avoid scraping or damaging them. Remove th ont cove (2) by puling it dowewards wth Acaution Upon reessembly the tangs correctly in the appropriate slots ‘Upon reassombly tighten the serows only medi ely. Be earful not to overtighton the sors, this wil damage the surounding plastic and painted components REMOVING THE FRONT SHIELD ead carefully PRECAUTIONS AND GENERAL INFORMATION. Poston te motoryceon the cere stand Femove the rnt cover (see REMOVING THE FRONT COVER} Remove the front rudquae (REMOVING THE FRONT MUDGUARO). LUnsrew anc remove he 4 crews (i ‘AcauTin Proceed with care Do net damage the tabs andor corresponding tab ste Handle painted part carefully, without scraping oF «damaging them LUnscew ane remove the 6 serews (2 that hte Inner ont shld othe aut fon ad | ra |Chassis ‘Searabeo 150 tat the hor (2) on ts mauning bot so that oes not scrape again! he shield when he shea is bong removes, Femove the use holder (2), Unsren and remove the screw (5). Remove he (8). Pal the outer sie (7) away fom te ontinner shied (8). [NOTE A tim tg wt be necessary to separate the ‘two componoris. Eneurs thatthe tabs snap out ‘dearly and ae nt damaged, as yeu pul these ‘comonents apart Aoaunon When rofiting, ft the tabs property Int thei slots @. REMOVING THE FOOTREST Read caretlly PRECAUTIONS AND GENERAL INFORMATION and FUEL. Postion the motorycle on he center stan Remove the footrest mats (1). Remove th ceil inspection cover (REMOVING ‘THE CENTRAL INSPECTION COVER), Unsere anc rave the 7 soem 2. [NOTE Tho fotowing operaions mustbecarod out onbath sides othe motorcycle eloase 002001Chassis Unsorow ae remove the 2 serene. Femove te footrest (3). REMOVING THE REAR FOOTRESTS Fad carefully PRECAUTIONS AND GENERAL INFORMATION. Psion he motorcyte onthe corer stan, AcauTon Be caretut not o injure your hands. NOTE The flowing instacton apply both Ee footrest ubber pad (1) manvaly Remove te lp ‘thera the pn from the a Famave te eo footrest (8 REMOVING ‘THE FLOOR PANEL LOWER GUARD Read carefully PRECAUTIONS AND GENERAL INFORMATION. Poston he moioreyele onthe conte stan Femave te footrest ma (1) Unsrew and remove the 2 screws (2 Scarabeo 150 Bolease 00, 2001-05‘Scarabeo 150 Unscrew and remove the sore (2) Remove the oor pane ower gars (8) caution Proceed with car, Do not damage the tabs andlor corresponding tab slots Handle painted parts carefully without seraping or <éamaging thom. REMOVING THE REAR-VIEW MIRRORS. ‘Soofuty road MAINTENANCE, Pace the vee an he contr star, (ee PLACING ‘THE VEHICLE ON THE STAND}, NOTE to righthand rearview mior nas a ightnand {head and he lthand mir aha end, ‘Theis o than case of acetal mpact tho res ‘ew mito wa ae bacovare, us rea Is rita propes poston, roi tin he epposte ase tion eal he rors propor located then stug up e nth DISASSEMBLY acauTion ‘When removing the mirrors (1), make sure that you alan agp on them to avol tong ham to rep: NOTE The lat mor as arigh-hand tucad. The ‘ohtminor hat a efthand tsa, Unerow a omens {Me roarvlew mir (1) (countercoctuise iaton for Tiel mor ana ano rtalon freight mr), REASSEMELY Screw the miro) in by turing it atest tre times {Urs (elocuse ratio or hee rrr and count ‘locke roan fo he ght mia, {cao the mir ()n sucha way © opie the ‘oarwar vb veer [NOTE The ont ior locking nuts provided wih Ine that dsinglshos trom the lot mir oekng rt Hele mers) ns poston y adustng the ocing rut) Glcnwse vlaion fo he et mor ng nut ‘unersocserotatn fo the mior xing ‘Awasning ‘After reassembly, correctly agus he rearview imimors and tighten the nua auch way that the Iiors are secute Faire thee this warning can provent yeu from seeing danger approsching fom Eehina‘and end to serous accion Comes aun Ne reflecting surtace (2) ofthe rear E faloasgco 204.05Chassis REMOVING THE FRONT FAIRING ead carefully HUINTENANCE, Pigs the vari on the centr stand, (58 PLACING. ‘THE VEHICLE ON THE STAND}, Unsero ane remove th two ses (1) Ferma the Wont par of fies 2). ‘caution Upon reassembly, tighton tho serows only meder- ely. Be careful not to over ighton the screws, this will damage the surrounding plastic and painted components. REMOVING THE HEADLIGHT ead carefully PRECAUTIONS AND GENERAL INFORMATION Psion he motorcyte onthe corto stan Remove the ont ang (REMOVING THE FRONT FAIRING), Faby unscrew te height beam adustmentscew Gh NOTE Repost ine ‘owing operation tom the char ‘ide a8 wel Unsere and remove the serw (2) ‘A.cauTON Proceed with care Do net damage the tbs andor coresponding tb ‘lea, Henao past and painted para earafuly, ‘without scraping or damaging them. Do not dam ‘age the lene Remove the headight eainer screw bushings Disconnect the lei! connection Remove he headlight 3) ogee with he drecton indestor, [NOTE Forinstuotons on romovng the bubs (02 CHANGING THE HEADLIGHT BULBS), Far instuc- fons on removing the tum signals (s08 REMOVING ‘THE TURN SIGNALS), REMOVING THE TURN SIGNALS ead carefully PRECAUTIONS AND GENERAL INFORMATION. Poss tho motoroyle onthe contr stand Remove the headight (REMOVING THE HEAD. UGH, Femove the headight elector, foloning thenstuc- tongin CHANGING THE HEADLIGHT BULBS, Disconnect he elecres!connacton (1). Unscrew and romove the eerws (2) ch.7. Scarabeo 190 Fioloass 00 2001-05Acauton Do net damage the tabs andor corresponding tb slots. Handle plastic and painted parts cartuly, ‘without seraping or damaging them, Putout the tum sana signals (8) REMOVING THE REAR LIGHT Read carefully PRECAUTIONS AND GENERAL INFORMATION. Postion the motoryce on th conte stand “AcauTION iit until the angine and exhaust mute cool down completely. Bittaanect te ectca connection (1) under ho Sate cormparnert and ease the ves from ele fine on the ram {iecan and remove the srews 2 along withthe tn Siena. Fetmove te tamght (9) togetner wit te un sna REMOVING THE DASHBOARD PANEL Read carefully PRECAUTIONS AND GENERAL INFORMATION, Potion the motoryco onthe cane stand Remove the front aking (REMOVING THE FRONT FAIRING), UUnsrow an move the sores (1) AcauTION Proceed with care Do not damage the tabs andior corresponding tab slots. Handle plastic and painted ports earetuly, Without seraping or damaging ther. Do not damage the lens. Using ata bade sxomdiver, gant ey, a soveral pis, roura te dash pane Separate the pan! (2) em be headlight Suppo) Aarove the panal (2 arabs sheen ack L Deri tS ea ea Saar et Release 09 2001-05 ch. 7REMOVING THE HEADLIGHT SUPPORT Read carefully PRECAUTIONS AND GENERAL INFORMATION. Poston te motoroyete onthe center stan Remove the ton ating (REMOVING THE FRONT FAIRING) Remove the dashboar panel (REMOVING THE DASHBOARD PANEL). Uncen remove the ser (1), Unseen and remove the sors (2) ‘caution Proceed with care. Do not damage the tabs andor corresponding tab ‘lots. Handle paste and pained parts caret, ‘without scraping or damaging them. Do not damage the ls. ‘Separate the heasight suppor (9), complete wih Discomect the elecieal connection 3). Remove the complete headlight suppér (3) NOTE I necessary, remove he headlight (REMDV: ING THE HEADLIGHT) and the ront tut gna (FENOVING THE FRONT TURN SIGNALS}. REMOVING THE HANDLEBAR COVER Read caretlly PRECAUTIONS AND GENERAL INFOsMATION. Poston ho motor on the conte stand Femova th font ang (REMOVING THE FRONT. Femavs the dashboard panel (REMOVING THE BASHSOARD PANEL) Ferrove he eagog?t suppor (REMOVING THE ft FEABLIaT SuPer UUncerew and remove the & crs (1) “AcauTion Proceed wih cre.Do not damage the tabs andor Corresponding ib set: Handa past ports reilly, witout scraping or damaging hem ch. 7. Beloase 00 2001-05Chassis [Scarabeo 150 Unscrew and remove the 2 screws (2) Femove the handisar cover (2) REMOVING THE DASHBOARD ead caretully PRECAUTIONS AND GENERAL INFORMATION. Postion he motoreyce on he Femove the handlobar cover HANDLEBAR COVER), Digconrecthe 2 eloctial connections, (1) and (2). Disconnect ine fachometsoometer eine) Remove the dashboard (0), pullng forward REMOVING THE LEFT HANDLEBAR. ELECTRICAL CONTROLS. ‘Rood carefully PRECAUTIONS AND GENERAL INFORMATION. Poston the motorycle on the centr stand. ‘Unscrew and remove the cores (1) hat cure the [eft ighlow beam selector fom below, Unscrew an remove the screw (2) above the contro ‘Separate he two covers, (3) and (8), and remove thom Free he wing tom the camps tat ht othe tame NOTE Prepare the same numberof new camps for reiting. Discoonet holt highow beam s “AcauTION ‘When reiting, make sure the connector is lugged in properly. Femove te let highow beam selector (6) lease 00 2001-05REMOVING THE LEFT HANDLEBAR ELECTRICAL CONTROLS ead caretlly PRECAUTIONS AND GENERAL INFORMATION Postion tha moloreyele onthe center sta Unscrew and remo the serous (1) tat soars the ‘over ote right higilow bean selector am Blow Unscrew and romave te scr (2) above Strat re eve, () =r a Free ine wing tom the clamps that xi he fae NOTE Prepare the same numberof new lamps for refit. biscornect the elecrial connector onthe ht hol Tow beam selector When refiting, make sue the connectors plugged in property. Persdee tage higvow beam se REMOVING THE HANDLEBAR ‘Road carefully PRECAUTIONS AND GENERAL INFORMATION, Rmave the handlebar cover (REMOVING THE HANDLEBAR COVER), Femave the dashboard (REMOVING THE DASH. BORRD), Femave te lacrical conte ante sight an lt handebars (REMOVING THE LEFT AND FIGHT HANDLEBAR ELECTRICAL CONTROLS), Loosen and remove the nt (1 Tightening torque for nut (1): 40 Nin (20 kgm) [29.5 FU. \winarawthe bl that attaches the handebar tothe fame (2) Take ofthe washer. Loosen ana remove the nt) Take outthe saat stow Femove the completa harlabar 6). ch.7 [ Searabeo 150Scarabeo 150 REMOVING THE FUEL TANK Read caretully PRECAUTIONS AND GENERAL INFORMATION and FUEL. Postion he matory one corer star Avan ‘Wait uni the engine and exhaust muffler coo! down completely. Remove the cena! nspcton cover (REMOVING ‘THE CENTRAL INSPECTION COVER), Rermove the sed comparnars (REMOVING THE FUEL TANK COVER SADDLE COMPARTMENT), warns itis necessary o run the engine in order to carry outa maintenance operation, make sure that ‘he area in which you ae operating Is propery, ventisted overrun the engine in enclosed spaces Nis necessary to work indoors, use an exhaust evacuation systom. Exhaust umes contain carbon monoxide, pol sonous gas that ean cause los of consclousness andeven death, Keep egareties, flames soars away tom the work fea ana trom the pace whore gasoline i store. Awarwnc ‘The engine and components ofthe exhaust sys- tom become very hot and remain hot for some {imp ator the engine has boon stepped. Before handling these components, woar insula Ing golves or wait unt the engine and the exhaust syetom have cooled down 100 NOT DISPOSE OF FUEL INTHE ENVIRON MENT. Postion th motoreyete on the oantr stand Stop the ergno an wat ott cal dow. {eta conane, big enough o hold he quanity of ue remaining nth tank and place on he ground {helo ofthe motorola, FRerove tha tol tak ca. Use a hand operated oump or similar system to empty the Wet out of ho tar Awanninc After emptying, close the tank cap. oloase 00 2001-05 ch7 |“To ompty the carburetor completely Romove the coral insoecon cover Place he too oro! the be (1) na cota. Working om te ent lf the motereyle, open the ‘cerourtor crn pl Under the chamber ‘ion al the tt inthe carburetor has come out Seow inthe oan seve (2) comely. ‘Accaurion ‘Screw the drain plug (2) in thoroughly to avoid {at leaks from the carburetor when filing up ath tu by losaningnge arin seu 2) Pour tha etn can, ease the sae plac. Remove he clamp () and disconnect the vacuum ose (8 love sneor Unserow ae remove tho Bot (8) that seeuos the tank othe tame, taking ofthe washer and nut ch.7. of h — Rolease 00 2001-05‘Searabeo 160 Remove the fel tank (10) wh he We! pump, by ‘moving tore and ting aut [NOTE tt nocessay, remove the fuel pump (RENOV- ING THE FUEL PUMP), REMOVING THE SADDLE LOCK Read carefully PRECAUTIONS AND GENERAL INFORMATION and FUEL. Raico up th sade (UNLOCKINGLOCKING THE SADDLE), Unserew and remove the wo screws (1), king ofthe bussinge, Holang on to he lok, remove the protective ca (2). ‘thar bs lek conrl cal (2) rom te ein, emo the sad lnk mechan ( REMOVING THE IGNITION SWITCHISTEERING LOCK ead carefully PRECAUTIONS AND GENERAL INFORMATION. Remove the nar rt sid (REMOVING THE INNER FRONT SHIELD) Dicontnea the sac lok abl (1). Disconnect the gntonsalteh ecto connector. Unscrew and remove te two screws (2. FRomove the ignlion etstering ck (3) Bi Release 00 2001-05 ch.7.Chassis REMOVING THE AIR BOX Read carefully PRECAUTIONS AND GENERAL INFORMATION. Awarnin. Walt uni the engine and exhaust mutter coo! down completely. Fomave tne sacce companment (REMOVING THE ‘SADOLE COMPARTMENT, Loosen the sore (1. With the tube 3) trom he camp (2). Acaumion Proceed with care. Do not force the felines. Lacon the sere (6) the claro (510 beable to ‘wher the ite hose (6), Femevo the carp (7) tom he blow-by tube (8). Remove the compte a box (9) NOTE Forinsrucions on cleaning the aie, REMOVING THE EXHAUST PIPE ead carefully PRECAUTIONS AND GENERAL INFORMATION. Postion te matoreyae onthe conto stand. ‘A waswna ait until the engine and exhaust mutler coo down completely. Remove the cota inspection cover (REMOVING THE CENTRAL INSPECTION COVER) Unscrew anc remove the two ns (1) fom thee faust mano. “Torque wrench seting for exhaust manifold nuts (9):30 Nim 22.1 Fb). ‘Acaurion ‘When refiting, replace the exhaust manifold ‘tle gasket with anew one. EG) cn7 Belease Ob 2001.5,Unerew an omave the tw sews 2) tha secre the mutt the Suppo. Tightening torque for screws (2) 27 tim (189 Feb) Femove th comsiete exhaust pipe (8) REMOVING THE EXHAUST PIPE SUPPORT ead carefully PRECAUTIONS AND GENERAL INFORMATION. Postion tha motoreyele onthe cote stand Avanwne Wat unt the engine and exhaust mutfler cool down completly Remove the exhaust pipe (REMOVING THE EX. HAUST PIPE), UUnscrow and move the two scr (1). Tightening torque for serews () 27 wm (199 Fibs) Unscrew and move the nut (2). ‘Tightning torque fr nat): ‘MO ne (61.1 Fibs). Remove tw exhaust pipe supper (2) ALcAUTION ‘Always replace the whee! nut with anew one ‘an refting REMOVING THE CENTER STAND esd carefully PRECAUTIONS AND GENERAL, INFORMATION, Awana Wait uni the engine and exhoust mutler cool ‘down completely Support the motoreyce so thet you can workin complete safety without the use of the contalran Ferme te lear banal loner qua (REMOVING THE FLOOR PANEL LOWER GUAPO}. Femove the vara arnt (REMOVING THE \VARIATOR AIR INTARE). 4200 2001.05 ch.7Chassi ‘Scarabeo 150 [NOTE The otowing cperatons must be petomed ‘tam tha le othe stand LUnccuple the sing (1) fom is hook onthe star (2). necro and remove sre (2) and Remove the center stand}, comple with support Unscrow an comeove the bot (7) an take othe selecceg it “Tightening torque fr bolt) 27 (1.8 Fb). Remove the center stan (5) rom the support (6 REMOVING ‘THE ENGINE CONNECTING ROD ‘Read carefully PRECAUTIONS AND GENERAL INFORMATION, awannnc Wait unt he engine and exhaust mufer cool ‘down compltey Support the motorcycle so that you can workin complete safety without the use ofthe center stand Inaction supporting the metoreyee om unde ath, aach to coum strane tbr propa so ‘hat the scooter wl not oat orvaré when tho gine connectg a is omoven. Femove te leer pane! ewer guard REMOVING ‘THE FLOOR PANEL LOWER GUARD). Fermove the vaateaiintke (REMOVING THE \VARIATOR AIR INTAKE), Femave te forest (REMOVING THE FOOTREST), Acaumon o not unserew the nut (1) that holds the comect- ing rod armconneeting rod bolt Unscrew and omove the rt (2) eae of the ‘washer “Tighiening torque for nut 2: 50 Nm (96.9 Fibs) Windraw te bl ch. 7‘Scarabeo 150 Unsere and remove the nut (6) and tke atthe washer (on he oppose se ln 8) ‘Tightening torque for nut (4) 50m (36.9 Fibs). Witharaw the pin (5) and ake of te washer. NOTE Repoat the folowing operations onthe other se of te motoroyce Unseen and remove the screw (6) andtake of he ‘washers (7) “Tightening torque for screw (6): 40 Nm (29.5 Ibs) Femove te connecting od (8) am undrneath to (ether wi he two ston blocks (9) andthe am (10) “Takeoff he two set block ana housings (11) with thalroushes (12), Acaunon Check the condition of the silent blocks (9). Itheres any deformation, erecking or other ‘signs of woat or deterioration, roplacs them. LUngerow and remove the aut (1), ‘Tightening torque for nut (13): 40 Nm (285 Fibs). ‘inhdrae the lento 4, (0) ating of te bushing ALcAUTION Ccheck whe condition ofthe bushings (14. tneces- sar, replace them. Unsere and remove the ut (15) and take ofthe washer (1), “Tightening torque for nut (15): 50 Nm (6.9 Fibs). War the bot (17), taking ff the washer (18) REMOVING THE FRONT MUDGUARD ead carefully PRECAUTIONS AND GENERAL INFORMATION. Psion the mooreyie onthe cote tan. Tightening torque for screws (1) 27 Ne (19.9 Fibs. Remove the front wheel (REMOVING THE FRONT WHEEL) olease 00 2001.05 ch.7.Chassis ‘Scarabeo 150 Unscrew and remove the sre (2) Remove he cabo guide (6 tre cable. the odometer Unsetaw and remove the 4 sores (5 Remove the mudguard protection (6), ‘Unscrew and remove te sere (7), Pul the ont udguara down try and vomove k from below (2 caution Proceed with care. Handle paint parte carefully, without eeraping ‘hem omg Release 00 2001.05Chassis ‘Scarabeo 150 FRONT WHEEL elease 0 200.05 oh |Chassis REMOVING THE FRONT WHEEL Read carefully PRECAUTIONS AND GENERAL INFORMATION. Avani. ‘Take care not to damage the brake Noses, dss and pads when ramouingraliting the whet Postion ho motaryot on the corer stand, wanna Position a block or support under the motorcycle 0 that ront whee sree ofthe ground and tet the motoreyeo le stable and wil pt fall backward len the front whee is removed. Lncorew ane remove the to serews (1) ermove the bake caliper by withdrawing itcatuily from Bebe 8c (2) Lacan the ser on he whee! epinde clamp (2h Leeson the whoa ping (wih abo wrench awanninc. ‘Observe the assembly order ofthe parts, washers ‘and spacer, in ordorto be able to reassemble them correctly. Hold the Tor woe! an takeout the axe (4) mar aly Remove the whee! Disongage th tab on he tachometerodomster (3) ove Acaurion Never touch the front brake lever after removing the brake caller from the alse ityou do, the ealper pistons may be pushed éown inther seats and brake fad wil be elle, “Torelt, (soe REFITTING) EEG! cs. 7 Release 00 2001.05 ‘Scarabeo 160Chassis CHANGING THE BEARINGS ead careully PRECAUTIONS AND GENERAL INFORMATION. Avaric Each time they are cisassembied the bearings ‘must be checked and, it necessary, renewed. Clean both sides ofthe hb wih coh Removal Work rom the let side of th whee insert lune att ers and fap onthe ena race othe gf bearng (1), moving te rte pots 90 with ach tap. you re caret, you can remove th boating withou, damaging Retrove the right bearing, and remove tne spss (2) Working rom tha et sie othe wheel using a which engagos the outer vaca of hate bear (3), lapitoutofts seat Reftting Working ror ho right sto of the wheel, place the boarng inthe wheel hub. acauTion Ensure thatthe bearing axis s perfect aligned wth the ub Using adit hat engages only the outer race of the bearing, gently tap the bearing ito place. neue tht iis completely seated against the Seat at the bottom ofthe Bearing recess. ‘Then, working from the lot side ofthe west, Insert the spacer, and, using an appropriate deft ‘hat engages the outside race ofthe beeing ony, lewis install he lef front wheel Bearing, NOTE Nover use a cet whic ouehes the bl capes or tll of he Bearing, rack he cet moderately saver! ines tha rbbor hammer unl he ight beating (1) fly ieee, Insert the space (2). Working tom holt oo tho more Repeat me tst vee eperatons fo he a sa 00 2001.05. ch.7