Professional Documents
Culture Documents
Scarabeo 500
Scarabeo 500
05/2006-00
www.serviceaprilia.com
workshopmanual
UK
8181024
INTRODUCTION 0
0-1
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INTRODUCTION
SCARABEO 500
SUMMARY
0.1. INTRODUCTION ............................................................................................................................................. 3
0.1.1. FOREWORD.......................................................................................................................................... 3
0.1.2. REFERENCE MANUALS....................................................................................................................... 4
0.1.3. ABBREVIATIONS/SYMBOLS/CONVENTIONS..................................................................................... 5
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INTRODUCTION
SCARABEO 500
0.1. INTRODUCTION
0.1.1. FOREWORD
This manual provides the information required for normal servicing.
This publication is intended for use by aprilia Dealers and their qualified mechanics; many concepts have been omitted
on purpose as their inclusion would be superfluous. Since complete mechanical explanations have not been included in
this manual, the reader must be familiar with basic notions of mechanics, as well as with basic repair procedures.
Without such familiarity, repairs and checks could be ineffective and even hazardous. Since the repair and vehicle check
instructions are not exhaustive, special care must be taken to avoid damage and injury. Piaggio & C. S.p.A. undertakes
to constantly improve the design of its products and the relevant literature to ensure maximum customer satisfaction. The
main technical modifications and changes in repair procedures are communicated to all aprilia dealers and agencies
worldwide. Such modifications will be entered in subsequent editions of the manual. Should you need assistance or
clarifications about the inspection and repair procedures, please contact the aprilia SERVICE DEPT., they will be glad to
give you any information on the matter, or supply you with any detail on updates and technical changes applied to the
vehicle.
Piaggio & C. S.p.A. reserves the right to make changes to its products at any time, barring any such changes as may
alter the essential features of a product as specified in the relevant manual.
All rights of storage using electronic means, reproduction and total or partial adaptation, whatever the means adopted,
are reserved in all countries.
Third parties' products are only mentioned for information purposes, and constitute no engagement.
Piaggio & C. S.p.A. is not liable in any way for the performance or use of these products.
DECA s.r.l.
via Vincenzo Giardini, 11 - 48022 Lugo (RA) - Italy
Tel. +39 - 0545 216611
Fax +39 - 0545 216610
E-mail: deca@vftis.spx.com
www.vftis.com
on behalf of:
Aprilia
via G. Galilei, 1 - 30033 Noale (VE) - Italy
Tel. +39 – (0)41 58 29 111
Fax +39 – (0)41 58 01 674
www.aprilia.com
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INTRODUCTION
SCARABEO 500
OWNER'S MANUALS
ENGINE CD
CHASSIS CD
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INTRODUCTION
SCARABEO 500
0.1.3. ABBREVIATIONS/SYMBOLS/CONVENTIONS
# = number
< = less than
> = greater than
≤ = less than or equal to
≥ = more than or equal to
~ = approximately
∞ = infinity
°C = degrees Celsius (centigrade)
°F = degrees Fahrenheit
± = plus or minus
a.c = alternating current
A = Ampere
Ah = Ampere per hour
API = American Petroleum Institute
AT = high voltage
AV/DC = Anti-Vibration Double Countershaft
bar = pressure measurement unit (1 bar = 100 kPa)
d.c. = direct current
cc = cubic centimetres
CO = carbon monoxide
CPU = Central Processing Unit
DIN = German industrial standards (Deutsche Industrie Norm)
DOHC = Double Overhead Camshaft
ECU = Electronic Control Unit
rpm = revolutions per minute
HC = unburnt hydrocarbons
ISC = Idle Speed Control
ISO = International Standardisation Organisation
kg = kilograms
kgm = kilograms per metre (1 kgm = 10 Nm)
km = kilometres
km/h = kilometres per hour
kΩ = kilo Ohm
kPa = kiloPascal (1 kPa = 0.01 bar)
KS = clutch side (from the German "Kupplungsseite")
kW = kilowatt
ℓ = litres
LAP = racetrack lap
LED = Light Emitting Diode
LEFT
SIDE = left side
m/s = metres per second
max = maximum
mbar = millibar (1 mbar = 0.1 kPa)
mi = miles
MIN = minimum
MPH = miles per hour
MS = flywheel side (from the German "Magnetseite")
MΩ = MegaOhm
N.A. = Not Available
N.O.M.M. = Motor Octane Number
N.O.R.M. = Research Octane Number
Nm = Newton metre (1 Nm = 0.1 kgm)
Ω = ohm
PICK-UP = pick-up
BDC = Bottom Dead Centre
TDC = Top Dead Centre
PPC = Pneumatic Power Clutch
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INTRODUCTION
SCARABEO 500
RIGHT
SIDE = right side
SAE = Society of Automotive Engineers
TEST = diagnostic check
T.B.E.I. = crown-head Allen screw
T.C.E.I. = cheese-head Allen screw
T.E. = hexagonal head
T.P. = flat head screw
TSI = Twin Spark Ignition
UPSIDE-
DOWN = inverted fork
V = volt
W = watt
Ø = diameter
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GENERAL INFORMATION
SCARABEO 500
GENERAL INFORMATION 1
1-1
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GENERAL INFORMATION
SCARABEO 500
SUMMARY
1.1. STRUCTURE OF THE MANUAL..................................................................................................................... 3
1.1.1. CONVENTIONS USED IN THE MANUAL ............................................................................................. 3
1.1.2. SAFETY WARNINGS............................................................................................................................. 4
1.2. GENERAL RULES........................................................................................................................................... 5
1.2.1. BASIC SAFETY RULES......................................................................................................................... 5
1.3. DANGEROUS ELEMENTS ............................................................................................................................. 8
1.3.1. WARNINGS ........................................................................................................................................... 8
1.4. RUNNING-IN ................................................................................................................................................. 11
1.4.1. RUNNING-IN........................................................................................................................................ 11
1.5. VEHICLE IDENTIFICATION .......................................................................................................................... 12
1.5.1. POSITION OF THE SERIAL NUMBERS ............................................................................................. 12
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GENERAL INFORMATION
SCARABEO 500
optional
catalytic version
- all versions
MP national certification
SF European certification (EURO 2 limits)
VERSION:
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GENERAL INFORMATION
SCARABEO 500
Safety warning. This symbol appears, whether in the manual or on the vehicle itself, to indicate a
personal injury hazard. Non-compliance with the indications given in the messages preceded by this
symbol may result in serious risks for your and other people’s safety and for the vehicle!
DANGER
Indicates a potential hazard which may result in serious injury or even death.
WARNING
Indicates a potential hazard which may result in minor personal injury or damage to the vehicle.
NOTE The word "NOTE" in this manual precedes important information or instructions.
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GENERAL INFORMATION
SCARABEO 500
DANGER
Exhaust gases contain carbon monoxide, which is extremely toxic if inhaled and may cause loss of
consciousness or even lead to death.
FUEL
DANGER
The fuel used in internal combustion engines is highly flammable and can become explosive under
particular conditions.
Refuelling and engine service should take place in a well-ventilated area with the engine stopped.
Do not smoke when refuelling or in the proximity of sources of fuel vapours, avoid flames, sparks and
any element that could ignite fuel or provoke explosions.
HIGH-TEMPERATURE COMPONENTS
The engine and the components of the exhaust system become very hot and remain hot for some time after the engine
has been stopped.
Before handling these components, wear insulating gloves or wait until the engine and the exhaust system have cooled
down.
DANGER
Wear latex gloves when servicing.
Gear fluid may cause serious damage to the skin if handled daily and for long periods.
Wash your hands carefully after handling engine oil.
Take it to the filling station where you usually buy it or to an oil salvage centre.
Wear latex gloves when servicing.
BRAKE FLUID
WARNING
When handling the brake fluid, take care not to spill it on the plastic, rubber or painted parts, since it
can damage them. When carrying out the maintenance operations on the braking system, use a clean
cloth to cover these parts.
Always wear safety goggles when working on the braking system.
The brake fluid is highly irritant. Avoid contact with your eyes.
If the brake fluid gets in contact with your eyes, carefully wash them with fresh water and immediately
seek medical advice.
COOLANT
Coolant contains ethylene glycol that is flammable, under certain conditions. When ignited, ethylene glycol produces
invisible flames that might cause burns.
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GENERAL INFORMATION
SCARABEO 500
DANGER
Take care not to spill coolant onto hot engine parts and exhaust system. It may ignite and produce
invisible flames.
Wear latex gloves when servicing.
Although toxic, it has a sweet taste that might attract animals. Never leave coolant in open container
or in a position easily reachable by animals.
Do not remove radiator cap when engine is still hot. Coolant is under pressure and might cause burns.
DANGER
The battery electrolyte is a toxic, caustic substance containing sulphuric acid and thus able to cause
severe burns in case of contact with the skin.
Always wear tight gloves and protective clothes when handling this fluid.
In case of contact with skin, rinse with plenty of fresh water.
Always use a protection for your eyes since even a very small amount of the battery fluid can cause
blindness. In the event of contact with your eyes, carefully wash them with water for fifteen minutes
and then consult immediately an eye specialist.
Should you accidentally drink some fluid, drink abundant water or milk, then drink magnesia milk or
vegetable oil and immediately seek medical advice.
The battery gives off explosive gases and must be kept away from flames and sources of ignition or
heat; do not smoke near the battery.
DANGER
Using bare flames is strictly forbidden when working on the motorcycle. Before servicing or
inspecting the motorcycle: stop the engine and remove the key from the ignition switch; allow for the
engine and exhaust system to cool down; where possible, lift the motorcycle using adequate
equipment placed on firm and level ground. Be careful of any parts of the engine or exhaust system
which may still be hot to the touch to avoid scalds or burns.
Do not put any vehicle parts into your mouth: vehicle components are not edible and some of them
are harmful or even toxic.
Unless expressly specified otherwise, assemblies are reassembled by reversing the dismantling
procedure. Where a procedure is cross-referred to relevant sections in the manual, proceed sensibly
to avoid disturbing any parts unless strictly necessary. Do not polish matt-painted surfaces with
polishing paste.
Never use fuel instead of solvent to clean the motorcycle.
Do not clean any rubber or plastic parts or the seat with alcohol, petrol or solvents. Clean with water
and mild detergent.
Always disconnect the battery negative (-) lead before soldering any electrical components.
When two or more persons service the same motorcycle together, special care must be taken to avoid
personal injury.
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GENERAL INFORMATION
SCARABEO 500
DISASSEMBLING THE COMPONENTS
- Never use pliers or similar tools to slacken and/or tighten nuts and bolts. Always use the suitable spanner.
- Mark all connections (hoses, wiring, etc.) with their positions before disconnecting them. Identify each connection
using a distinctive symbol or convention.
- Mark each part clearly to avoid confusion when refitting.
- Thoroughly clean and wash any components you have removed using a detergent with low flash point.
- Mated parts should always be refitted together. These parts will have seated themselves against one another in
service as a result of normal wear and tear and should never be mixed up with other similar parts on refitting.
- Certain components are matched-pair parts and should always be replaced as a set.
- Keep away from heat sources.
DANGER
Never reuse a circlip or snap ring. These parts must always be renewed once they have been
disturbed.
When fitting a new circlip or snap ring, take care to move the open ends apart just enough to allow
fitment to the shaft.
Make it a rule to check that a newly-fitted circlip or snap ring has located fully into its groove.
Never clean a bearing with compressed air.
NOTE All bearings must rotate freely with no hard spots or noise. Replace any bearings that do not meet these
requirements.
- Use ORIGINAL aprilia SPARE PARTS only.
- Use the specified lubricants and consumables.
- Where possible, lubricate a part before assembly.
- When tightening nuts and bolts, start with the largest or innermost nut/bolt and observe a cross pattern. Tighten
evenly, in subsequent steps until achieving the specified torque.
- Replace any self-locking nuts, gaskets, seals, circlips or snap rings, O-rings, split pins, bolts and screws which
have a damaged thread.
- Lubricate the bearings abundantly before assembly.
- Make it a rule to check that all components you have fitted are correctly in place.
- After repairing the motorcycle and after each service inspection, perform the preliminary checks, and then test ride
the motorcycle in a private estate area or in a safe area away from traffic.
- Clean all mating surfaces, oil seal edges and gaskets before assembly. Apply a thin layer of lithium grease along
the edges of oil seals. Fit oil seals and bearings with the marking or serial number facing outwards (in view).
ELECTRICAL CONNECTORS
To disconnect the electrical connectors, follow the procedures below. Failure to comply with these procedures may lead
to irreparable damage to the connector and the wiring as well.
If present, press the special safety hooks.
WARNING
Do not pull cables to disconnect the two connectors.
• Grasp the two connectors and disconnect them by pulling them in the two opposite directions.
• In case of dirt, rust, moisture, etc., thoroughly clean the inside of the connectors with compressed air.
• Make sure that the cables are correctly fitted inside the connector terminals.
NOTE The two connectors have just one correct positioning. Make sure to position them in the right direction.
• Then fit the two connectors. Make sure they are correctly coupled (a click will be heard if hooks are present).
DANGER
Always remember that the tightening torque settings of all wheel, brake, wheel shaft and other
suspension parts play a fundamental role to ensure vehicle safety. Make sure that these values are
always within the specified limits.
Check fastening parts tightening torque settings at regular intervals. Upon reassembly, always use a
torque wrench.
Failure to comply with these recommendations could lead to the loosening and detachment of one of
these parts with a consequent locking of the wheel or other serious troubles affecting the vehicle
manoeuvrability, and thus the risk of falls and serious injuries or death.
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GENERAL INFORMATION
SCARABEO 500
DANGER
The fuel used to operate engines is highly flammable and becomes explosive under particular
conditions.
Refuelling and engine service should take place in a well-ventilated area with the engine stopped.
Do not smoke when refuelling or in the proximity of sources of fuel vapours, avoid flames, sparks and
any element that could ignite fuel or provoke explosions.
Take care not to spill fuel out of the filler, or it may ignite when in contact with hot engine parts.
In the event of accidental fuel spillage, make sure the affected area is fully dry before starting the
engine. Fuel expands from heat and when left under direct sunlight.
Never fill the fuel tank up to the brim. Tighten the filler cap securely after each refuelling.
Avoid contact with skin. Do not inhale vapours. Do not swallow fuel. Do not transfer fuel between
different containers using a hose.
DO NOT DISPOSE OF FUEL IN THE ENVIRONMENT.
KEEP AWAY FROM CHILDREN.
Use only premium grade unleaded petrol, min. O.N. 95 (RON) and 85 (MON).
LUBRICANTS
DANGER
A good lubrication ensures the vehicle safety.
Failure to keep the lubricants at the recommended level or the use of a non-suitable new and clean
type of lubricant can lead to the engine or gearbox seizure, thus causing serious accidents, personal
injury or even death.
Gear fluid may cause serious damage to the skin if handled daily and for long periods.
Wash your hands carefully after use.
Do not dispose of oil in the environment.
Take it to the filling station where you usually buy it or to an oil salvage centre.
WARNING
When filling the vehicle with this oil, take care not to spill it out. Immediately clean spilt oil, or it might
damage the vehicle paintwork.
In case of contact with oil, the tyres surface will become very slippery, thus becoming a serious
danger for your safety.
In case of leaks, do not use the vehicle. Check and trace the cause of leaks and proceed to repair.
ENGINE OIL
DANGER
Engine oil may cause serious damage to the skin if handled daily and for long periods.
Wash your hands carefully after use.
Do not dispose of oil in the environment.
Dispose of engine oil through the nearest waste oil reclamation firm or through the supplier.
Wear latex gloves when servicing.
DANGER
Front suspension response can be modified to a certain extent by changing damping settings and/or
selecting a particular grade of oil. Standard oil viscosity: SAE 20W. Different oil grades can be
selected to obtain a particular suspension response (choose SAE 5W for a softer suspension, 20W for
a stiffer suspension).
The two grades can also be mixed in varying solutions to obtain the desired response.
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GENERAL INFORMATION
SCARABEO 500
BRAKE FLUID
NOTE This vehicle is fitted with front and rear disc brakes. Each braking system is operated by an independent hydraulic
circuit. The information provided below applies to both braking systems.
DANGER
Do not use the vehicle in case brakes are worn out or do not work properly. The brakes are the parts
that most ensure your safety and for this reason they must always be perfectly working. Failure to
comply with these recommendations will probably lead to a crash or an accident, with a consequent
risk of personal injury or death.
A wet surface reduces brakes efficiency.
DANGER
In case of wet ground the braking distance will be doubled, since both brakes and tyre grip on the
road surface are extremely reduced by the water present on the road surface.
Any water on brakes, after washing the vehicle or driving on a wet road surface or crossing puddles
or gips, can wet brakes so as to greatly reduce their efficiency.
Failure to comply with these recommendations may lead to serious accidents, with a consequent risk
of severe personal injuries or death.
Brakes are critical safety components. Do not ride the vehicle in case brakes are not working at their
best.
Check for brakes proper operation before every trip.
Brake fluid is an irritant. Avoid contact with eyes or skin.
In the event of accidental contact, wash affected body parts thoroughly. In the event of accidental
contact with eyes, contact an eye specialist or seek medical advice.
DO NOT RELEASE BRAKE FLUID INTO THE ENVIRONMENT.
KEEP AWAY FROM CHILDREN.
When handling brake fluid, take care not to spill it onto plastic or paint-finished parts or they will
damage.
DANGER
Do not use any brake fluids other than the specified type. Never mix different types of fluids to top up
level, as this will damage the braking system.
Do not use brake fluid from containers which have been kept open or in storage for long periods.
Any sudden changes in play or hardness in the brake levers are warning signs of problems with the
hydraulic circuits.
Ensure that the brake discs and brake linings have not become contaminated with oil or grease. This
is particularly important after servicing or inspections.
Make sure the brake lines are not twisted or worn.
Prevent accidental entering of water or dust into the circuit.
Wear latex gloves when servicing the hydraulic circuit.
DISC BRAKES
DANGER
The brakes are the parts that most ensure your safety
and for this reason they must always be perfectly working; check them before every trip.
A dirty disc soils the pads.
Dirty pads must be replaced, while dirty discs must be cleaned with a high-quality degreaser.
Perform the maintenance operations with half the indicated frequency if the vehicle is used in rainy or
dusty areas, on uneven surfaces or for racing.
Check brake pads for wear.
When the brake pads wear out, the level of the fluid decreases to automatically compensate for their
wear.
The front brake fluid reservoir is located on the right handlebar, near the front brake lever.
The rear brake fluid reservoir is located under the right fairing.
Do not use the vehicle if the braking system leaks fluid.
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GENERAL INFORMATION
SCARABEO 500
COOLANT
DANGER
Coolant is toxic when ingested, contact with eyes or skin may cause irritation.
In the event of contact with your skin or eyes, rinse repeatedly with abundant water and seek medical
advice. In the event of ingestion, induce vomiting, rinse mouth and throat with abundant water and
seek medical advice immediately.
DO NOT RELEASE INTO THE ENVIRONMENT.
KEEP AWAY FROM CHILDREN.
DANGER
Take care not to spill coolant onto hot engine parts. It may ignite and produce invisible flames. Wear
latex gloves when servicing.
Do not ride when coolant is below the minimum level.
Coolant mixture is a 50% solution of water and antifreeze. This is the ideal solution for most operating temperatures and
provides good corrosion protection.
This solution is also suited to the warm season, as it is less prone to evaporative loss and will reduce the need for top-
ups.
In addition, less water evaporation means fewer minerals salts depositing in the radiator, which helps preserve the
efficiency of the cooling system.
When the temperature drops below zero degrees centigrade, check the cooling system frequently and add more
antifreeze (up to 60% maximum) to the solution, if needed.
Use distilled water in the coolant mixture. Tap water will damage the engine.
Refer to the chart given below and add water with the quantity of antifreeze to obtain a solution with the desired freezing
point:
TYRES
WARNING
If tyres are excessively inflated, the vehicle will be hard, difficult and uncomfortable to ride.
In addition, the roadworthiness, mainly on wet surfaces and during cornering, will be impaired.
Flat tyres (insufficient pressure) can slip on the rim and make you lose the control of the vehicle.
In this case too, both vehicle roadworthiness, manoeuvrability and brake efficiency will be impaired.
Tyres changing, repair, maintenance and balancing must be carried out by specialised technicians
using suitable equipment.
When new, tyres can have a thin slippery protective coating. Drive carefully for the first kilometres
(miles).
Never use rubber treating substances on tyres.
In particular, avoid contact with fluid fuels, leading to a rapid wear.
In case of contact with oil or fuel, do not clean but change the tyres.
DANGER
Some of the factory-assembled tyres of this vehicle are provided with wear indicators.
There are several kinds of wear indicators.
For more information on how to check the wear, contact your Dealer.
Visually check if the tyres are worn and in this case have them changed.
If a tyre deflates while driving, stop immediately.
Avoid hard brakings or moves and do not close throttles too abruptly.
Slowly close the throttle grip, move to the edge of the road and use the engine brake to slow down
until coming to a halt.
Failure to comply with these recommendations may lead to accidents, with a consequent risk of
personal injuries or death.
Do not install tyres with air tube on rims for tubeless tyres and vice versa.
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GENERAL INFORMATION
SCARABEO 500
1.4. RUNNING-IN
1.4.1. RUNNING-IN
Correct engine running-in is essential to ensuring proper performance and durability.
If possible, drive on hilly roads and/or roads with many bends, so that the engine, the suspensions and the brakes
undergo a more effective running-in.
During running-in, change speed.
In this way the components are first "loaded" and then "relieved" and the engine parts can thus cool down.
Even if it is important to stress the engine components during running-in, take care not to exceed.
WARNING
Only after the first 1000 km (621 mi) of running-in is it possible to obtain the best acceleration
performance from the vehicle.
DANGER
After the first 1000 km (621 mi), have the checking operations indicated in the column "After running-
in" carried out by an aprilia Authorised Dealer, see REGULAR SERVICE INTERVALS CHART, in order
to avoid hurting yourself or other people and/or damaging the vehicle.
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GENERAL INFORMATION
SCARABEO 500
ENGINE NUMBER
The engine number is stamped on the rear end, next to left
shock absorber.
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GENERAL TECHNICAL INFORMATION
SCARABEO 500
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GENERAL TECHNICAL INFORMATION
SCARABEO 500
SUMMARY
2.1. TECHNICAL INFORMATION .......................................................................................................................... 3
2.1.1. TECHNICAL DATA ................................................................................................................................ 3
2.1.2. SCHEDULED MAINTENANCE CHART................................................................................................. 5
2.1.3. LUBRICANT CHART.............................................................................................................................. 7
2.1.4. TIGHTENING TORQUE SETTINGS ...................................................................................................... 8
2.1.5. ARRANGEMENT OF THE MAIN ELEMENTS ..................................................................................... 13
2.1.6. INSTRUMENT PANEL OPERATION ................................................................................................... 15
2.2. SCHEDULED MAINTENANCE...................................................................................................................... 18
2.2.1. BRAKING SYSTEM ............................................................................................................................. 18
2.2.2. AIR FILTER.......................................................................................................................................... 20
2.2.3. COOLANT............................................................................................................................................ 21
2.2.4. TRANSMISSION FLUID....................................................................................................................... 22
2.2.5. ENGINE OIL......................................................................................................................................... 24
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GENERAL TECHNICAL INFORMATION
SCARABEO 500
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GENERAL TECHNICAL INFORMATION
SCARABEO 500
BRAKES
Front Disc - Ø 260 mm (10.236 in) - with hydraulic transmission
Rear Twin disc - front Ø 260 mm (10.236 in) / rear Ø 240 mm
(9.449 in)
WHEEL RIMS
Type in light alloy
Front 16" x 3.00"
Rear 14" x 4.5"
TYRES
Type tubeless
Front 110/70 -16" 56S tubeless
Rear 150 / 70 - 14" 66S tubeless
STANDARD INFLATION PRESSURE
Front 220 kPa (2.2 bar)
Rear 220 kPa (2.2 bar)
INFLATION PRESSURE WITH PASSENGER
Front 220 kPa (2.2 bar)
Rear 230 kPa (2.3 bar)
IGNITION
Type C.D.I. / induction type
Spark advance Variable, managed by control unit
SPARK PLUG
Standard CHAMPION RG6YC
As an alternative NGK - CR7EKB
Spark plug gap 0.7 - 0.8 mm (0.028 - 0.031 in)
ELECTRIC SYSTEM
Battery 12 V - 14 Ah
Fuses 20 - 15 - 3 A
Generator (with permanent magnet) 14 V – 380 W
BULBS
Low/high beam 12V - 55 W / 12V - 55 W
Front parking light 12 V – 5 W
Rear/front turn indicators light 12V - 10W (rear)/ 12V - 10W (front)
Tail / brake lights 12V - 5W / 21W
Number plate light 12 V – 5 W
WARNING LIGHTS
Instrument panel lighting LED
Turn indicators LED
Engine oil pressure LED
Low beam LED
High beam LED
Fuel reserve LED
Coolant high temperature indicator LED
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GENERAL TECHNICAL INFORMATION
SCARABEO 500
EVERY 2 years
Coolant - change
Brake fluid - change
At 10000 km (6214 mi), 30000 km (18641 mi), 50000 km (31068 mi) and at 70000 km (43496 mi)
Safety fastening points - check
Spark plug - change
Belt - change
Throttle control - adjust
Air filter - check
Belt comp.air filter - check
Engine oil filter - change
Valve clearance - check
Electric system and battery - check
Coolant level - check
Brake fluid level - check
Engine oil - change
Brake pads - check for wear
Converter rollers/ sliders - change
Tire pressure and wear - check
Vehicle and braking system test - road test
Hub oil - check
Idling speed - adjust
Stand striker roller - change
Suspensions - check
Steering - check
Braking system tubes sealing - visual check
Crankcase breather - drain
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GENERAL TECHNICAL INFORMATION
SCARABEO 500
At 20000 km (12427 mi), 40000 km (24855 mi), 60000 km (37282 mi) and at 80000 km (49710 mi)
Safety fastening points - check
Driven pulley bush
Spark plug - change
Belt - change
Throttle control - adjust
Air filter - check
Belt comp.air filter - check
Engine oil filter - change
Valve clearance - check
Electric system and battery - check
Coolant level - check
Brake fluid level - check
Engine oil - change
Brake pads - check for wear
Converter rollers/ sliders - change
Tire pressure and wear - check
Vehicle and braking system test - road test
Hub oil - check
Idling speed - adjust
Stand striker roller - change
Crankcase breather - drain
Suspensions - check
Steering - check
Injection system tubes sealing - visual check
Fuel filter - check
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GENERAL TECHNICAL INFORMATION
SCARABEO 500
LUBRICANT PRODUCT
Engine oil RECOMMENDED: 4T FORMULA RACING, SAE 5W - 40.
As an alternative to recommended fluids, top brand oils meeting or
exceeding A.P.I. SJ
specifications can be used.
Transmission fluid RECOMMENDED: GEAR SYNTH, SAE 75W - 90.
As an alternative to recommended fluid, top brand oils meeting or
exceeding A.P.I. GL3
specifications can be used.
Fork oil RECOMMENDED: FORK 5W or FORK 20W.
When you wish to obtain an intermediate response between those offered
by FORK 5W and FORK 20W oils, you may mix the
different products as follows:
SAE 10W = FORK 5W 67% of volume, + FORK 20W 33%
of volume.
SAE 15W = FORK 5W 33% of volume, + FORK 20W 67%
of volume.
Bearings and other lubrication RECOMMENDED: GREASE SM2.
points As an alternative to recommended grease, use top brand rolling bearing
grease that will resist a temperature range of -30°C (-22°F) + 140°C
(284°F), with dropping point 150°C (302°F) - 230°C (446°F), high corrosion
protection, good resistance to water and oxidisation.
Battery terminals Use neutral grease or Vaseline.
Brake fluid RECOMMENDED: BRAKE 5.1 DOT 5 (compatible DOT 4).
NOTE Do not mix different makes or types of oil without having checked
bases compatibility.
As an alternative to the recommended product, top brand brake fluid
meeting or exceeding SAE J1703, NHTSA 116 DOT 4, ISO 4925
specifications for synthetic brake fluid can be used.
Engine coolant RECOMMENDED: COOL.
As an alternative to the recommended product, top brand brake fluid
meeting or exceeding CUNA NC 956-16 specifications for ethylene glycol
coolant can be used.
2-7
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GENERAL TECHNICAL INFORMATION
SCARABEO 500
TIGHTENING
QUANTITY
SETTINGS
SCREW /
TORQUE
NOTES
(Nm)
NUT
DESCRIPTION
BRAKING SYSTEM
Rear brake master cylinder to handlebar fastening 2 TCEI screw M6x25 10
Throttle control to front brake master cylinder fastening 2 TCEI screw M6x25 10
2-8
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GENERAL TECHNICAL INFORMATION
SCARABEO 500
TIGHTENING
QUANTITY
SETTINGS
SCREW /
TORQUE
NOTES
(Nm)
NUT
DESCRIPTION
FRONT SUSPENSION
TIGHTEN
TO 25 Nm
THEN
Fork nut 1 Nut 10
SLACKEN
AND TAKE
TO 10 Nm
Fork lock nut 1 Nut 38
Fork hub fastening 1 Screw 10
Front mudguard fastening 3 TE screw M6x16 10
HANDLEBAR ASSY
Handlebar to fork fastening 1 Nut M10 50
STAND ASSY
Centre stand to frame fastening 2 Nuts M10 30
Side stand to frame fastening 1 Nut M10 25
COOLING SYSTEM ASSY
Radiator to frame fastening 1 TE screw M6X20 10
Electric fan support to radiator fastening 1 TE screw M5X12 5
Pump/radiator hose ties fastening 2 Tie 3
Radiator cap fastening 1 Cap M14 20
Electric fan support bracket fastening 2 Nut M6 5
Head/radiator hose ties fastening 2 Tie 3
REAR WHEEL ASSY
Rear wheel to hub fastening 5 TE screw M8x40 35
Rear wheel fastening 1 Nut 120
REAR SUSPENSION ASSY
Rh/Lh shock absorber support fastening 4 Nut M8 25
Rh/Lh shock absorber fastening 4 Nut M10 40
TANK ASSY
Fuel tank to frame fastening 2 TE screw M6X20 10
Front fuel tank support fastening 2 TE screw M8X16 25
Rear fuel tank support fastening 2 TE screw M8X16 25
Fuel lines fastening 1 TBEI screw M5x16 5
Expansion tank support 1 TCEI screw M5X16 5
Expansion tank fastening 1 TBEI screw M6X16 5
FRAME ASSY
Rh/Lh rider platform connection plate fastening 4 TE screw M6X12 10
Coil to Lh rider platform connection plate fastening 2 Nut M6 10
Radiator cowl to frame fastening 2 TBEI screw M6X16 5
Rear arch to frame fastening 2 TE screw M8X16 25
Rh/Lh passenger footpegs support fastening 4 TCEI screw M8X25 25
Rh/Lh passenger footpegs support fastening 2 TCEI screw M8x35 25
2-9
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GENERAL TECHNICAL INFORMATION
SCARABEO 500
TIGHTENING
QUANTITY
SETTINGS
SCREW /
TORQUE
NOTES
(Nm)
NUT
DESCRIPTION
2 - 10
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GENERAL TECHNICAL INFORMATION
SCARABEO 500
TIGHTENING
QUANTITY
SETTINGS
SCREW /
TORQUE
NOTES
(Nm)
NUT
DESCRIPTION
TCB screw
Inner shield to side shield halves and tunnel fastening 5 3
5.55X22
Bag hook fastening 2 TCB screw 4.2X25 1
Seat hinge to seat fastening 4 Nut M6 5
TCB screw
Spark plug seat cover fastening 2 2
5.5X15.9
Spark plug seat cover fastening 1 TCB screw 4.2X16 1
SELF-TAPPING
Rh/Lh multipurpose net to shield fastening 4 1
screw 3.9X14
Glove compartment door frame to door fastening 4 Screw 3.9X10 1,5
Plate to glove compartment door fastening 2 Screw 3.9X10 1,5
SELF-TAPPING
Plate to fuel filler flap fastening 1 1
screw 3.9X14
SELF-TAPPING
Glove compartment door to shield fastening 4 1
screw 3.9X14
SELF-TAPPING
Fuel filler flap to tunnel fastening 2 1,5
screw 3.9X14
FRONT CHASSIS ASSY
SELF-TAPPING
Air breather grid to rh shield half fastening 3 1
screw 3.9X14
SELF-TAPPING
Air breather grid to lh shield half fastening 3 1
screw 3.9X14
Shield half to rh radiator cowl fastening 3 TCB screw 4.2X16 1
Shield half to lh radiator cowl fastening 3 TCB screw 4.2X16 1
TCB screw
Tunnel fastening 4 2
5.55X22
Front mudguard fastening 4 TE screw M6x16 10
2 - 11
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GENERAL TECHNICAL INFORMATION
SCARABEO 500
TIGHTENING
QUANTITY
SETTINGS
SCREW /
TORQUE
NOTES
(Nm)
NUT
DESCRIPTION
SELF-TAPPING
Dog to Tunnel fastening 2 1
screw 3.9X14
2 - 12
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GENERAL TECHNICAL INFORMATION
SCARABEO 500
Key:
1. Expansion tank
2. Coolant expansion tank cap
3. Integrated brake fluid reservoir
4. Air filter
5. Transmission cover
6. Left passenger footpeg
7. Centre stand
8. Side stand
9. Spark plug
10. Central inspection cover
11. Warning horn
2 - 13
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GENERAL TECHNICAL INFORMATION
SCARABEO 500
Key:
2 - 14
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GENERAL TECHNICAL INFORMATION
SCARABEO 500
2 - 15
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GENERAL TECHNICAL INFORMATION
SCARABEO 500
TRIP METER RESET
From the trip meter function, hold the MODE button for more
than 3 seconds to reset it.
SELECTING KM OR MILES
From the battery function, hold the MODE button for more
than 10 seconds to toggle between Km and miles reading
both for odometer and tachometer (if on the display).
While button is being pressed, indication of current unit of
measurement (Km or Miles) will flash with a frequency of
1Hz.
If button is released before 10 seconds have elapsed, unit of
measurement is not changed.
More functions
SOFTWARE VERSION
Software version is displayed when battery is activated.
SERVICE
When the vehicle is started, just after ignition check routine,
the Service icon will flash for 5 seconds if the following
scheduled Service is less than 300 Km (200 Miles) away.
As soon as the vehicle reaches set Service mileage, the
Service icon is fixed on until it is reset.
SERVICE RESET
The service icon is reset by holding the MODE button for
more than 10 seconds when the key is turned on: the
instrument panel will not show any warning for the first 5
seconds, then the Service icon will flash with a frequency of
1Hz during the next 5 seconds.
ODOMETER RESET
In order to allow end of line inspections, it should be possible
to reset the odometer (only once) within the first 200Km (124
mi) of mileage.
Resetting procedure is the same as Service reset.
If odometer is reset during the end of line inspections, even
the service counter should be reset, so that it will first come
on when odometer indicates 1000km (621 mi).
DIGITAL ODOMETER
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GENERAL TECHNICAL INFORMATION
SCARABEO 500
TRIP RESET TRIP 1/TRIP 2
• Press and hold (MODE) button (1) for more than three
seconds when selected TRIP meter is displayed.
NOTE The displayed function will be reset.
TURN INDICATORS
This light should use a green LED that turns on at the same
time as the turn indicators.
FUEL RESERVE
This light should use an orange LED that turns on when the
vehicle is using the fuel reserve.
OIL ALARM
This light should use a red LED that indicates oil pressure
alarm.
HIGH BEAM
This light should use a blue LED and should turn on when
the high beam is on.
EFI
This light should use a red LED and indicates failures of the
engine control unit.
EXTERNAL ANTITHEFT SYSTEM
This light should use a red LED and is piloted by a possible
external antitheft system (i.e. it is not managed by the
microprocessor)
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GENERAL TECHNICAL INFORMATION
SCARABEO 500
2 - 18
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GENERAL TECHNICAL INFORMATION
SCARABEO 500
BLEEDING THE REAR BRAKE
2 - 19
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GENERAL TECHNICAL INFORMATION
SCARABEO 500
REMOVAL
• Position the vehicle on the centre stand.
• Unscrew and remove the nine screws (1).
CLEANING
WARNING
Do not use petrol or inflammable solvents to
wash the filtering element, in order to avoid
fires or explosions.
Use compressed air only.
Blow the filtering element with compressed air.
NEVER SMEAR THE FILTERING ELEMENT
WITH OIL. Any oil seeping into the belt casing
would damage the belt and cause it to slip.
2 - 20
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GENERAL TECHNICAL INFORMATION
SCARABEO 500
2.2.3. COOLANT
CHECKING AND TOPPING UP
WARNING
Wait for the engine to cool down before
checking or topping up coolant level.
If not so:
• Loosen the filler plug (1) (by turning it anticlockwise),
without removing it.
• Wait a few seconds in order to release any residual
pressure.
• Unscrew and remove the plug (1).
WARNING
Do not add additives or other substances to the
fluid.
WARNING
If coolant level drops too quickly or the
expansion tank is empty, check the cooling
circuit for leaks.
2 - 21
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GENERAL TECHNICAL INFORMATION
SCARABEO 500
CHECK
WARNING
Allow several minutes for the engine and
exhaust system to cool down.
TOPPING UP
2 - 22
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GENERAL TECHNICAL INFORMATION
SCARABEO 500
CHANGE
WARNING
Allow several minutes for the engine and
exhaust system to cool down.
2 - 23
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GENERAL TECHNICAL INFORMATION
SCARABEO 500
CHECK
WARNING
Allow several minutes for the engine and
exhaust system to cool down.
Stop the engine and let it cool down, in order to allow the oil
to flow into the oil pan and to cool down.
NOTE Failure to perform the operations described above
may result in the incorrect measurement of the engine oil
level.
• Unscrew and extract the plug/dipstick (1).
• Clean the part in contact with the oil with a clean cloth.
• Tighten the plug/dipstick (1) completely, screwing it
into the filling hole (2).
• Withdraw the plug/dipstick (1) again and read the oil
level on the dipstick itself:
DANGER
Never exceed the "MAX" mark or let oil level
drop below the "MIN" mark, as this may lead to
severe engine damage.
TOPPING UP
2 - 24
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GENERAL TECHNICAL INFORMATION
SCARABEO 500
CHANGING ENGINE OIL AND OIL FILTER
NOTE Position the vehicle on firm and flat ground.
• Position the vehicle on the centre stand.
WARNING
Allow several minutes for the engine and
exhaust system to cool down.
WARNING
Used oil contains substances that are very
dangerous for the environment. Dispose of
used oil in accordance with applicable
regulations.
• Unscrew and remove the oil drain plug (3) and let all
engine oil flow inside the container.
• Install a new oil cartridge filter. Lubricate the filter O-
rings with oil before installation.
• Screw and tighten the engine oil drain plug (3).
2 - 25
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FUEL SYSTEM
SCARABEO 500
FUEL SYSTEM 3
3-1
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FUEL SYSTEM
SCARABEO 500
SUMMARY
3.1. FUEL TANK ..................................................................................................................................................... 3
3.1.1. FUEL SUPPLY SYSTEM DIAGRAM...................................................................................................... 3
3.1.2. REMOVING THE TANK ......................................................................................................................... 4
3.2. AIR FILTER ..................................................................................................................................................... 6
3.2.1. REMOVING THE AIR BOX .................................................................................................................... 6
3.3. DIAGNOSIS..................................................................................................................................................... 8
3.3.1. AXONE................................................................................................................................................... 8
3-2
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FUEL SYSTEM
SCARABEO 500
Key:
1. Fuel tank
2. Tank plug
3. Fuel level sensor
4. Fuel pump
5. Fuel pump ring nut seal
6. Fuel pump ring nut
7. Heat shield
8. Washer
9. Plate
10. Rubber block
11. Clip M6
12. Flanged Hex.screw M6X20
13. Fuel line D5.5X10
14. Washer 6.6X18X1.6
3-3
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FUEL SYSTEM
SCARABEO 500
3-4
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FUEL SYSTEM
SCARABEO 500
3-5
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FUEL SYSTEM
SCARABEO 500
3-6
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FUEL SYSTEM
SCARABEO 500
3-7
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FUEL SYSTEM
SCARABEO 500
3.3. DIAGNOSIS
3.3.1. AXONE
SYMBOL SCREEN
ISO
DEVICES ACTIVATION
ERRORS DISPLAY
ADJUSTABLE PARAMETERS
FREEZE FRAME
APPROXIMATE UNIT OF
SCREEN DESCRIPTION NOTES
VALUES MEASURE
ISO
Mapping code with reversed figures. If
all figures are nought, it means that the
ECU is empty (not mapped): it is
Aprilia hardware XXXXXX000 -
necessary to upload the suitable
mapping (see note concerning mapping
parameter)
Aprilia software - Meaningless field
Revision number XX -
Engine 500 cc - Single-cylinder engine, 500cc
Manufactured on dd/mm/yy - ECU date of manufacture
Mapping XXXXXX - Mapping code stored in ECU.
Date last mapping was loaded:
Programming date dd/mm/yy -
day/month/year
ID code for the PC or Axone tester that
loaded the latest mapping. In this 5.0.2
Last programmer XXXXX - version, the code shown is not correct:
to see it correctly, go to ISO page that
appears when selecting REPROGRAM
3-8
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FUEL SYSTEM
SCARABEO 500
APPROXIMATE UNIT OF
SCREEN DESCRIPTION NOTES
VALUES MEASURE
ENGINE
PARAMETER
READING
Water temperature - °C Measured with sensor on engine
Temperature measured at engine
intake (sensor in throttle housing). Note
Air temperature - °C
that the temperature at the instrument
panel is measured by a different sensor
Measured with crankshaft speed
Engine rpm - rpm
sensor
The ECU attempts to bring the engine
Target idle rpm 1700 rpm to this target speed (depending on
engine temperature).
Ignition advance - ° Ignition advance relative to TDC
Trimmer TPS
Stepper (idle) motor position, example
Idle motor 50 Steps
value measured with warm engine
Battery voltage - V Voltage measured at battery terminals
Engine phase number within
which more than a tooth
0/1 1 if many teeth are missing
was missed since the
beginning of the trip
Engine phase number within
which just a tooth was
0/1 1 if one tooth is missing
missed since the beginning
of the trip
Actual to target steps Difference between target and actual
Steps
difference steps of the stepper motor
The value must vary around 1 when the
ECU uses the oxygen sensor signal to
Lambda correction 1 -
keep combustion close to the
stoichiometric value
Voltage of the signal of the Lambda
Lambda sensor 100-900 mV sensor: this is a fixed value when the
circuit is interrupted
Injection time - ms Injector activation time
Atmospheric pressure of air (for
Atmospheric pressure 760 mmHg
mapping)
Parameter for self-adjustment of
Partial load self-adaptation mg/cc
lambda sensor when under partial load
Parameter for self-adjustment of
Idle control self-adaptation mg/cc
lambda sensor at idle speed
Parameter for self-adjustment of
Gain control adaptation %
lambda sensor at full load
3-9
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FUEL SYSTEM
SCARABEO 500
APPROXIMATE UNIT OF
SCREEN DESCRIPTION NOTES
VALUES MEASURE
DEVICE
STATUS
Engine status OFF / rotating - Engine stationary or in rotation
Synchronized if the ECU detects
Synchronized/Not
Signal panel - correct synchronisation (by way of
sync
crankshaft speed sensor)
Idle/full load on/off ON when engine is idling
ON if the ECU is using the lambda
Lambda sensor ON on/off sensor signal to maintain stoichiometric
combustion
ADJUSTABLE
PARAMETERS
Throttle position self- Simply press the enter button to save
learning the closed throttle position in memory
Reset self-adjusting lambda sensor
Self-adaptive parameter parameters (in the event of installation
reset of a new engine, a new lambda sensor
or a new injector)
Press "enter" to transfer errors from the
memory (MEM) to the historical record
(STO). The next time Axone is
Error clearing
connected to the ECU, the errors in the
historical record (STO) will no longer be
displayed
The device is activated: in the event
that the device is not activated
Fuel pump
successfully this will be immediately
indicated in the Axone screen
The device is activated: in the event
that the device is not activated
Coil
successfully this will be immediately
indicated in the Axone screen
The device is activated: in the event
that the device is not activated
Revolution counter
successfully this will be immediately
indicated in the Axone screen
The device is activated: in the event
that the device is not activated
Injectors
successfully this will be immediately
indicated in the Axone screen
The device is activated: in the event
that the device is not activated
Electric fan
successfully this will be immediately
indicated in the Axone screen
The device is activated: in the event
that the device is not activated
Stepper motor
successfully this will be immediately
indicated in the Axone screen
3 - 10
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FUEL SYSTEM
SCARABEO 500
APPROXIMATE UNIT OF
SCREEN DESCRIPTION NOTES
VALUES SIZE
ERRORS
DISPLAY
In the event of an interruption in the
Throttle - -
throttle position sensor signal
In the event of an interruption in the
Pressure - -
atmospheric pressure sensor signal
Appears if the sensor signal circuit is
Lambda sensor - -
interrupted
Open in the sensor, the circuit or the
Water temperature - -
relative connectors
Open in the sensor, the circuit or the
Air temperature (°C): - -
relative connectors
Battery voltage - -
Open in the sensor, the circuit or the
Injector - -
relative connectors
Open in the sensor, the circuit or the
Coil - -
relative connectors
Open in the sensor, the circuit or the
Idle motor - -
relative connectors
Fuel pump relay - -
Open in the sensor, the circuit or the
Electric fan - -
relative connectors
Self-adaptive parameters
RAM memory ECU internal error
ROM memory ECU internal error
EEPROM ECU internal error
Microprocessor ECU internal error
If the crankshaft speed sensor is
Signal panel - - disconnected this error will not be
displayed
ECU initialisation
ECU should be initialised in case important engine parts (valves, cylinder, camshaft), exhaust system parts, ECU
components, fuel feed system parts,
lambda sensor parts are replaced.
The three self-adaptive correction factors for lambda control concerning injection time are electronically reset.
• Select:”initialisation”.
• Ensure that the throttle is fully home
• Press ENTER “ “.
• Turn the key to “OFF” and allow at least 30 seconds.
3 - 11
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ENGINE
SCARABEO 500
ENGINE 4
4-1
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ENGINE
SCARABEO 500
SUMMARY
4.1. ENGINE ........................................................................................................................................................... 3
4.1.1. REMOVING THE ENGINE FROM THE FRAME.................................................................................... 3
4.1.2. INSTALLING THE ENGINE ................................................................................................................. 17
4-2
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ENGINE
SCARABEO 500
4.1. ENGINE
4.1.1. REMOVING THE ENGINE FROM THE FRAME
• Position the vehicle on the centre stand.
• Remove the tail guard, see (REMOVING THE TAIL
GUARD)
4-3
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ENGINE
SCARABEO 500
4-4
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ENGINE
SCARABEO 500
4-5
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ENGINE
SCARABEO 500
• Set up the lift hoist and fasten the vehicle suitably with
the lifting slings.
4-6
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ENGINE
SCARABEO 500
4-7
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ENGINE
SCARABEO 500
4-8
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ENGINE
SCARABEO 500
4-9
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ENGINE
SCARABEO 500
4 - 10
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ENGINE
SCARABEO 500
4 - 11
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ENGINE
SCARABEO 500
4 - 12
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ENGINE
SCARABEO 500
4 - 13
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ENGINE
SCARABEO 500
4 - 14
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ENGINE
SCARABEO 500
4 - 15
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ENGINE
SCARABEO 500
4 - 16
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ENGINE
SCARABEO 500
4 - 17
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ENGINE
SCARABEO 500
• Set the silent block with washer and tighten the nut.
4 - 18
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ENGINE
SCARABEO 500
• Set the rear brake line guide and spacer, then tighten
its screw.
4 - 19
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ENGINE
SCARABEO 500
4 - 20
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ENGINE
SCARABEO 500
4 - 21
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ENGINE
SCARABEO 500
4 - 22
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ENGINE
SCARABEO 500
4 - 23
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ENGINE
SCARABEO 500
• Fit the hose stop washer and then fit and tighten the
fuel lines retaining screw.
4 - 24
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ENGINE
SCARABEO 500
4 - 25
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ENGINE
SCARABEO 500
• Set the right shock absorber screw and tighten the nut.
4 - 26
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ENGINE
SCARABEO 500
• Fit and tighten the securing screw from the oil recovery
flange.
4 - 27
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ENGINE
SCARABEO 500
• Working on the left side, fit and tighten the two side
securing screws on rear mudguard with washers.
• Working on the right side, fit and tighten the two side
securing screws on rear mudguard with shims.
4 - 28
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ENGINE
SCARABEO 500
4 - 29
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CYCLE PARTS
SCARABEO 500
CYCLE PARTS 5
5-1
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CYCLE PARTS
SCARABEO 500
SUMMARY
5.1. OUTER STRUCTURES................................................................................................................................... 3
5.1.1. REMOVING THE SEAT ......................................................................................................................... 3
5.1.2. REMOVING THE FRONT COVER ........................................................................................................ 4
5.1.3. REMOVING THE TAIL GUARD ............................................................................................................. 5
5.1.4. REMOVING THE HELMET COMPARTMENT ....................................................................................... 9
5.1.5. REMOVING THE FOOTREST ............................................................................................................. 13
5.1.6. REMOVING THE INSTRUMENT PANEL ............................................................................................ 14
5.1.7. REMOVING THE HEADLIGHT ............................................................................................................ 15
5.1.8. REMOVING THE SEAT RELEASING SYSTEM .................................................................................. 17
5.2. EXHAUST SYSTEM ...................................................................................................................................... 18
5.2.1. REMOVING THE EXHAUST SYSTEM ................................................................................................ 18
5.3. FRONT WHEEL............................................................................................................................................. 20
5.3.1. FRONT WHEEL DIAGRAM ................................................................................................................. 20
5.3.2. REMOVING THE FRONT WHEEL ...................................................................................................... 21
5.4. REAR WHEEL ............................................................................................................................................... 22
5.4.1. REAR WHEEL DIAGRAM.................................................................................................................... 22
5.4.2. REMOVING THE REAR WHEEL ......................................................................................................... 23
5.5. BRAKING SYSTEM....................................................................................................................................... 26
5.5.1. BRAKING SYSTEM DIAGRAM............................................................................................................ 26
5.5.2. CHANGING THE PADS ....................................................................................................................... 28
5.5.3. REMOVING THE BRAKE FORCE DISTRIBUTION............................................................................. 30
5.6. FRONT FORK ............................................................................................................................................... 31
5.6.1. FRONT FORK DIAGRAM .................................................................................................................... 31
5.6.2. REMOVING THE FORK LEGS ............................................................................................................ 32
5.6.3. DRAINING OIL..................................................................................................................................... 34
5.6.4. DISASSEMBLING THE FORK............................................................................................................. 36
5.6.5. FILLING OIL......................................................................................................................................... 38
5.6.6. CHECKING THE COMPONENTS ....................................................................................................... 40
5.6.7. REASSEMBLING THE FORK.............................................................................................................. 41
5-2
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SCARABEO 500
5-3
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CYCLE PARTS
SCARABEO 500
WARNING
Proceed with care.
Do not damage the tabs and/or their seats.
When the front cover is removed you can gain access to:
- expansion tank;
- control unit;
- immobilizer;
- turn indicator lamps;
- voltage regulator,
- horn;
- relay
- bank angle sensor;
5-4
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SCARABEO 500
5-5
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SCARABEO 500
5-6
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SCARABEO 500
5-7
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SCARABEO 500
5-8
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SCARABEO 500
5-9
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SCARABEO 500
5 - 10
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SCARABEO 500
5 - 11
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5 - 12
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5 - 13
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SCARABEO 500
5 - 14
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SCARABEO 500
5.1.7. REMOVING THE HEADLIGHT
• Loosen and remove the securing screw from the
headlight frame.
WARNING
Proceed with care.
Do not damage the tabs and/or their seats.
5 - 15
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SCARABEO 500
5 - 16
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5 - 17
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5 - 18
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SCARABEO 500
5 - 19
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CYCLE PARTS
SCARABEO 500
Key:
1. Wheel shaft
2. Odometer sensor
3. Right oil seal
4. Right bearing
5. Wheel
6. Inner spacer
7. Left bearing
8. Left oil seal
9. Brake discs
10. Left spacer
11. Right spacer
NOTE Grease wheel shaft (1).
5 - 20
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SCARABEO 500
5 - 21
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SCARABEO 500
Key:
1. Complete wheel
2. Split pin
3. Cap
4. Nut
5. External spacer
6. Screw
7. Washer
8. Washer
9. Inner spacer
10. Wheel hub
11. Brake disc
5 - 22
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SCARABEO 500
5 - 23
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5 - 24
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5 - 25
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5 - 26
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SCARABEO 500
Key:
5 - 27
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SCARABEO 500
WARNING
These operations apply to both brake callipers.
WARNING
Always change both pads and ensure they are
correctly in place inside the calliper.
Do not reverse retainer (2) position upon
reassembly.
5 - 28
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CYCLE PARTS
SCARABEO 500
REAR BRAKE
WARNING
On spring is an arrow that should always be
pointing in the direction of travel.
WARNING
Always change both pads and ensure they are
correctly in place inside the calliper.
5 - 29
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SCARABEO 500
5 - 30
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Key:
5 - 31
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5 - 32
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5 - 33
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WARNING
The slider and sleeve assembly is filled with oil:
do not turn it upside-down or excessively tilt it
during disassembly.
5 - 34
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5 - 35
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• Slide off the damper rod (2) from the slider and
remove the spring (3).
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SCARABEO 500
5 - 37
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WARNING
Do not reuse oil that was previously drained.
5 - 38
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SCARABEO 500
5 - 39
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SCARABEO 500
OUTER SLEEVE
• Inspect the sliding surface for scoring and/or
scratching. Eliminate minor scoring with wet sand paper
(grain size 1).
• Replace the stanchion if badly scored.
• Check for stanchion buckling using a dial gauge.
• Replace the stanchion if buckled beyond the
service limit.
DANGER
NEVER attempt to straighten a buckled
stanchion as this would weaken the overall
structure leading to a dangerous riding
condition.
SLIDER
• Inspect for damage and/or cracking. Replace if
damaged.
• Change any component which is badly worn or
damaged.
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SCARABEO 500
WARNING
Ensure that no foreign matter enters inside the
sleeve and slider.
NOTE Before refitting the seals and bushings, smear them
with a film of fork oil.
5 - 41
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SCARABEO 500
5 - 42
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COOLING SYSTEM
SCARABEO 500
COOLING SYSTEM 6
6-1
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SCARABEO 500
SUMMARY
6.1. COOLING SYSTEM ........................................................................................................................................ 3
6.1.1. COOLING SYSTEM DIAGRAM ............................................................................................................. 3
6.1.2. CHANGING THE COOLANT ................................................................................................................. 4
6.1.3. REMOVING THE EXPANSION TANK ................................................................................................... 5
6-2
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COOLING SYSTEM
SCARABEO 500
Key:
1. Radiator
2. Expansion tank
3. Expansion tank support
4. Head-radiator hose
5. Pump-radiator hose
6. Electric fan mount
7. Electric fan
8. Spacer bushing
9. Top rubber block
10. Bottom rubber block
11. Clip M5
12. Flanged Hex.screw M5X12
13. Plug
14. Washer 6.6X18X1.6
15. Flanged Hex.screw M6X20
16. Bushing
17. Flanged Hex.screw M5X12
18. Clip M5
19. Clip M6
20. Flanged self-locking nut M6
21. Clamp D.16 24X8
22. Clamp D.16 24X8
23. Hose clamp
24. Expansion tank plug
25. Aluminium washer 14X22X1
26. Filler rubber element
27. Flanged TBEI screw M6X16
6-3
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SCARABEO 500
FILLING
6-4
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SCARABEO 500
6-5
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ELECTRICAL SYSTEM
SCARABEO 500
ELECTRICAL SYSTEM 7
7-1
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ELECTRICAL SYSTEM
SCARABEO 500
SUMMARY
7.1. ELECTRIC COMPONENTS ............................................................................................................................ 3
7.1.1. CHECKING THE ELECTRICAL COMPONENTS .................................................................................. 3
7.1.2. WIRING DIAGRAM ................................................................................................................................ 5
7-2
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SCARABEO 500
7-3
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SCARABEO 500
Key:
7-4
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SCARABEO 500
7-5
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SCARABEO 500
Key: WIRE COLOUR CODING
7-6
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30033 Noale (VE) Italy
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