2001 Aprilia 120S/154S/177S Scarabeo Workshop Manual – PDF DOWNLOAD

Description

2001 Aprilia 120S/154S/177S Scarabeo Workshop Manual – PDF DOWNLOAD

FILE DETAILS:

2001 Aprilia 120S/154S/177S Scarabeo Workshop Manual – PDF DOWNLOAD

Language : English
Pages : 140
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

2001 Aprilia 120S/154S/177S Scarabeo Workshop Manual – PDF DOWNLOAD

• This Workshop Manual contains information, data, and procedures necessary for servicing and repairing ROTAX type 120/1, 54/1, 77 engines. It is intended for use by professional mechanics who have been properly trained in the maintenance of these engines and have access to all common and special tools required for this work.
• If any procedure, data, or information in this manual is unclear, please contact Aprilia Service at the address or phone number provided below.
• The information in this Workshop Manual is current as of the date of publication. Since BOMBARDIER-ROTAX and Aprilia constantly strive to improve their scooter motors and scooters, changes are continuously introduced as new engines are produced. Therefore, some of the information in this manual may not apply to the scooter you are servicing.
• To ensure you always have the latest BOMBARDIER-ROTAX and Aprilia information, contact Aprilia Service. While this manual has been carefully compiled by the engineering and service departments of BOMBARDIER-ROTAX and Aprilia, we cannot guarantee the accuracy or applicability of all the material in this manual.

TABLE OF CONTENTS:

2001 Aprilia 120S/154S/177S Scarabeo Workshop Manual – PDF DOWNLOAD

Foreword 2
Important information
Recurrent symbols 6
General precautions and safety rules 6
Parts – list 9
Engine serial number – position 9
Technical data type 120 Leonardo and 120 Scarabeo 10
Technical data type 154 Leonardo and 154 Scarabeo 12
Technical data type 177 Scarabeo 14
Engine servicing schedule 16
Servicing and repair requirements 16
General notes on servicing and repair procedures 18
Fault finding 20
Service tools, equipment, sealing and lubricating agents 27
Standard tools 30
Measuring instruments 30
Fasteners 30
Sealing and lubricating agents 31
Torque wrench settings 34
Oil circuit 39
Repairs without removing engine 40
Removing engine from frame 41
Positioning engine on stand 42
Dismantling the engine
Starter motor — remove 43
Variator cover— remove 43
Carburetor hose and valve cover — remove 44
Locking crankshaft at top dead center 45
Timing chain — check 47
Chain tensioner and timing gear — remove 47
Cylinder head — remove 48
Chain guide and chain tension guide — remove 49
Cylinder — remove 49
Piston — remove 50
Oil filter and oil pressure switch — remove 51
Ignition and electric starter gearing — remove 51
Oil pump — remove 53
Water pump — remove 53
Chain tension guide and timing chain — remove 55
Oil strainer — remove 55
Variator — remove 56
Oil pressure valve 58
Transmission — remove 58
Half crankcase — separate 61
Crankshaft — remove 62
Servicing procedures
Crankcase 63
Half crankcase, flywheel side (MS) — flywheel side servicing 65
Half crankcase, clutch side — removal and refitting of plain bearings,
ball bearings, oil seal, etc 69
Transmission cover — servicing 76
Crankshaft 80
Transmission 82
Variator, primary drive side — check 83
Secondary drive 87
Timing gear 91
Chain guide and chain tension guide 92
Oil pump and water pump gearing 92
Oil pressure retaining valve 94
Cylinder 95
Piston and piston pin 95
Piston rings 97
Cylinder head 99
Valves 102
Valve seats 103
Rocker arms 105
Thermostat — check (Leonardo 120 only) 107
Valve cover 108
Ignition 109
Ignition cover 112
Spark plug 113
Electric starter gearing 114
Idle gear 115
Starter motor 115
Reassembling the engine
Half crankcase, flywheel side 116
Half crankcase, clutch side 117
Oil strainer and magnetic drain plug — refit 123
Piston — refit 124
Cylinder — refit 125
Chain guide and chain tension guide — refit 127
Cylinder head — refit 127
Chain tensioner — refit 128
Valve clearance — adjust 129
Oil filter — refit 130
Flywheel side components — refit 130
Water pump, idle gear and ignition cover — refit 131
Carburetor hose — refit 134
Starter motor — install 134
Variator cover — refit 134
Refitting engine onto frame 135
Filling 135
Engine test 137

S.S 16/03/2025