Page 1 SERVICE STATION MANUAL 854190 SCARABEO 500...
Page 2: Char
The descriptions and illustrations given in this publication are not binding; While the basic characteristics as described and illustrated in this manual remain unchanged, aprilia reserves the right, at any time and without being required to update this publication beforehand, to make any changes to components, parts or accessories, which it considers necessary to improve the product or which are required for manufacturing or construction reasons.
Page 3 SERVICE STATION MANUAL SCARABEO 500 NOTE Provides key information to make the procedure easier to understand and carry out. CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle. WARNING Refers to specific procedures to carry out to prevent injuries to the repairer. Personal safety Failure to completely observe these instructions will result in serious risk of personal injury.
Page 5 INDEX OF TOPICS CHAR HARACTERISTICS TOOL OOLING MAIN AINTENANCE ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE NGINE INJEC NJECTION SUSP USPENSIONS BRAK SYS RAKING SYSTEM COOL SYS OOLING SYSTEM CHAS HASSIS PRE DE DELIVERY...
Page 6 INDEX OF TOPICS CHAR HARACTERISTICS...
Page 7: Safety Rules
SCARABEO 500 Characteristics Rules Safety rules GENERAL PRECAUTIONS AND INFORMATION When repairing, dismantling and reassembling the vehicle, follow the recommendations given below carefully. CAUTION USE OF NAKED FLAMES IS FORBIDDEN DURING ALL TYPES OF OPERATION. BEFORE START- ING ANY MAINTENANCE OPERATION OR INSPECTION ON THE VEHICLE, SWITCH OFF THE ENGINE AND REMOVE THE KEY.
Page 8 SCARABEO 500 Characteristics The engine and the components of the exhaust system can get very hot and remain hot for some time even after the engine has been switched off. Before handling these components, make sure that you are wearing insulating gloves or wait until the engine and the exhaust system have cooled down.
Page 9 SCARABEO 500 Characteristics RINSE THEM CAREFULLY WITH WATER FOR FIFTEEN MINUTES, THEN SEE AN EYE SPECIAL- IST AS SOON AS POSSIBLE. IF IT IS ACCIDENTALLY SWALLOWED, DRINK LARGE QUANTITIES OF WATER OR MILK, FOL- LOWED BY MILK OF MAGNESIA OR VEGETAL OIL, AND SEEK MEDICAL ADVICE IMMEDIATE- THE BATTERY RELEASES EXPLOSIVE GASES.
Page 10: Section
NOTE BEARINGS MUST BE ABLE TO ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE, OTH- ERWISE THEY NEED REPLACING. • Use only ORIGINAL aprilia SPARE PARTS. • Comply with lubricant and consumables usage guidelines. • Lubricate parts (whenever possible) before reassembling them.
Page 11 SCARABEO 500 Characteristics • In presence of dirt, rust, humidity etc., clean the connector's internal parts carefully, using a pressurised air jet. • Make sure that the cables are correctly linked to the connector's internal terminal ends. NOTE THE TWO CONNECTORS CONNECT ONLY FROM ONE SIDE; CONNECT THEM THE RIGHT WAY ROUND.
Page 12: Vehicle Identification
For the best functioning of the engine the temperature of the coolant fluid should register in the central zone of the appropriate gauge. If the needle enters the red zone, stop the engine, allow it to cool, and check the level of the fluid; if it is normal, contact an Official aprilia Dealer. CAUTION DO NOT USE YOUR VEHICLE IF THE COOLANT LEVEL IS BELOW THE MINIMUM LEVEL MARKED "MIN".
Page 13 SCARABEO 500 Characteristics Chassis number The chassis number is stamped on the front frame; to read it, open the glove-box and remove the snap-on protection cover. Engine number The engine number is stamped on the rear side, next to the left shock absorber. Dimensions and mass WEIGHT AND DIMENSIONS Specification...
Page 14 SCARABEO 500 Characteristics Specification Desc./Quantity Max. width 770 mm (30.3 in) Max. height (to top fairing) 1.380 ÷ 1.420 mm (54.3 ÷ 55.9 in) Saddle height 785 mm (30.9 in) Wheelbase 1.540 mm (60.2 in) Minimum ground clearance 215 mm (8.5 in) Kerb weight (in running order) 194 kg (427.7 lb) Engine...
Page 15 SCARABEO 500 Characteristics Capacities CAPACITY Specification Desc./Quantity Fuel (reserve included) 13.2 l (3.48 gal) Fuel reserve 3 l (0.79 gal) Engine oil change and engine oil filter replacement 1700 cm³ (103.74 cu.in) Transmission oil 250 cm³ (15.256 cu.in) Coolant 1.7 l Seats Vehicle max.
Page 16: Wheels And Tyres
SCARABEO 500 Characteristics Specification Desc./Quantity Rear suspension travel 100 mm (3.94 in) Brakes BRAKES Specification Desc./Quantity Front brake Ø 260 mm (10.236 in) disc brake with hydraulic transmission Rear brake Double disc - front: Ø 260 mm (10.236 in) / rear: 240 mm (9.449 in) Wheels and tyres WHEELS AND TYRES...
Page 17: Exhaust System Unit
SCARABEO 500 Characteristics Name Torque in Nm Filter casing support fixing screw Starter motor cable fixing nut Starter motor retainers 11 ÷ 13 Rear brake calliper support fixing screw Nut fixing the rear brake disc to the hub Muffler plate-engine fixing nut Filter casing intake sleeve clamp to engine retainer Screw fixing the filter casing to the rear mudguard Screw fixing the filter casing to the engine support...
Page 18 SCARABEO 500 Characteristics Name Torque in Nm Screw fixing the electric fan support to the radiator Pump/ radiator hose clamp retainer Radiator cap retainer Nut fixing the electric fan support clamp Retainers for head/ radiator hose clamps Screw fixing the electric fan to the radiator REAR WHEEL UNIT Name Torque in Nm...
Page 19 SCARABEO 500 Characteristics Name Torque in Nm Self-tapping screw fixing the glove-box light switch to the glove-box Nut fixing the starter motor cable to the relay Nut fixing the battery cable to the starter motor re- Self-tapping screw fixing the antitheft control unit to the chassis Self-tapping screw fixing the connector clamp to the antitheft device...
Page 20 SCARABEO 500 Characteristics Name Torque in Nm Screw fixing the glove-box lid frame to the lid Screw fixing the bracket to the glove-box lid Self-tapping screw fixing the bracket to the fuel cap Self-tapping screw fixing the glove-box lid to the shield Self-tapping screw fixing the fuel cap lid to the tun- Self-tapping screw fixing the tab support...
Page 21 SCARABEO 500 Characteristics Name Torque in Nm Self-tapping screw fixing the instrument panel to the panel Self-tapping screw fixing the front headlamp ring Self-tapping screw fixing the instrument panel to the handlebar Self-tapping screw fixing the instrument panel to the ring nut FRONT WHEEL UNIT Name Torque in Nm...
Page 22 SCARABEO 500 Characteristics TRANSMISSION COVER Name Torque in Nm Driven pulley nut 92 - 100 Driving pulley nut 160 - 175 Anti-flapping roller screw 16.7 ÷ 19.6 Transmission cover M8 retainers 23 ÷ 26 M6 Retainer 11 ÷ 13 Anti-flapping roller retainer 17 - 19 Clutch ring nut 65 - 75...
Page 23 SCARABEO 500 Characteristics Cylinder - piston assy. HEIGHT AT WHICH THE PISTON SHOULD BE MEASURED Specification Desc./Quantity 10 mm (0.393 in) 43 mm (1.69 in) CYLINDER-PISTON Specification Desc./Quantity Cylinder Ø C 94+0.018-0.01 Piston Ø P 93.968±0.014 COUPLING CATEGORIES Name Initials Cylinder Piston Play on fitting...
Page 24 SCARABEO 500 Characteristics Piston rings * Fit piston rings «2» and «3» with the mark «TOP» facing up. ** Position the port in the piston rings as shown in this figure. *** Value «A» of the sealing ring inside the cylinder. Check the size of the sealing ring opening: Compression ring: 0.15 ÷...
Page 25 SCARABEO 500 Characteristics Oil scraper ring: Standard coupling clear- ance: 0.01÷0.06 mm Maximum clearances allowed after use: 0.10 If clearances measured exceed the maximum val- ues specified in the table, the piston should be replaced with a new one. Crankcase - crankshaft - connecting rod Crankshaft bearing diameter.
Page 26 SCARABEO 500 Characteristics CRANKSHAFT / CONNECTING ROD AXIAL CLEARANCE Name Description Dimensions Initials Quantity Transmission-side 1 ± 0.025 D = 0.20 ÷ 0.50 shoulder Half-shaft, trans- 20.9 - 0.05 D = 0.20 ÷ 0.50 mission side Connecting rod 22-0.10 - 0.15 D = 0.20 ÷...
Page 27 SCARABEO 500 Characteristics • Measure the diameter of bushings «A» at the three positions indicated in the figure. • Measure the diameter of crankshaft bearings «B». • Check that diametral clearance «A-B» is within the pre-set gap. Characteristic Diametral clearance 0.025 ÷...
Page 28 SCARABEO 500 Characteristics Characteristic Crankshaft-crankcase axial clearance: 0.1 ÷ 0.405 mm Slot packing system Shimming system to control the compression ratio MEASUREMENT «A» IS A PROTRUSION OR RECESS VALUE OF THE PISTON CROWN COMPARED WITH THE CYLINDER PLANE. MEASUREMENT «A» ALLOWS TO DETER- MINE THE THICKNESS OF GASKET «B»...
Page 29 SCARABEO 500 Characteristics Products ECOMMENDED PRODUCTS TABLE Product Description Specifications AGIP CITY HI TEC 4T Engine oil SAE 5W-40, API SL, ACEA A3, JASO MA Synthetic oil AGIP GEAR SYNTH Gearbox oil SAE 75W-90, API GL4, GL5 Synthetic oil AGIP FORK 7.5W Fork oil AGIP GREASE SM2 Lithium grease with molybdenum...
Page 30 INDEX OF TOPICS TOOL OOLING...
Page 31 SCARABEO 500 Tooling SPECIFIC TOOLS Stores code Description 001467Y002 Driver for bearing with OD 73 mm 001467Y006 Pliers to extract 20-mm bearings 001467Y007 Driver for bearings with OD 54 001467Y008 Pliers to extract Ø 17-mm bear- ings 001467Y014 Pliers to extract Ø 15-mm bear- ings 001467Y031 Driver...
Page 32 SCARABEO 500 Tooling Stores code Description 001467Y034 Pliers to extract Ø 15-mm bear- ings 001467Y035 Driver for bearings with OD 47 020074Y Supporting base for checking crankshaft alignment 020151Y Air heater 020150Y Air heater support AP8140181 Fuel pressure check tool 020262Y Crankcase splitting strip TOOL - 32...
Page 33 SCARABEO 500 Tooling Stores code Description 020306Y Punch for fitting valve sealing rings 020329Y Mity-Vac vacuum pump 020330Y Stroboscopic light for timing checking 020331Y Digital multimeter 020335Y Dial gauge magnetic support TOOL - 33...
Page 34 SCARABEO 500 Tooling Stores code Description 020357Y 32 x 35 mm adaptor 020358Y 37 x 40 mm adaptor 020359Y 42 x 47 mm adaptor 020360Y 52 x 55 mm adaptor 020363Y 20-mm guide for oil seal 020364Y 25-mm guide TOOL - 34...
Page 35 SCARABEO 500 Tooling Stores code Description 020375Y 28 x 30 mm adaptor 020376Y Adaptor handle 020382Y012 bushing (valve removing tool) 020382Y Tool for removing valve cotters fitted with part 012 020412Y 15-mm guide 020431Y Valve oil seal extractor TOOL - 35...
Page 36 SCARABEO 500 Tooling Stores code Description 020424Y Punch to fit driven pulley roller casing 020434Y Fitting for oil pressure check 020439Y 17-mm guide AP8140259 Tool for fitting/removing the clutch on the driven pulley 020456Y Ø 24-mm adaptor AP8140595 Axone + battery charger (230V 50Hz) TOOL - 36...
Page 37 SCARABEO 500 Tooling Stores code Description AP8202311 Axone + battery charger (110V 60Hz) 020467Y Flywheel extractor 020468Y Piston fitting ring 020470Y Pin snap ring fitting tool 020471Y Pin for countershaft timing 020472Y Flywheel lock wrench TOOL - 37...
Page 38 SCARABEO 500 Tooling Stores code Description 020474Y Driving pulley lock wrench 020475Y Piston position checking tool 020476Y Stud bolt set 020477Y 37-mm adaptor 020478Y Punch for roller casing 020479Y Countershaft lock wrench TOOL - 38...
Page 39 SCARABEO 500 Tooling Stores code Description 020480Y Fuel pressure check kit 020481Y Adaptor cable harness 020482Y Engine support 020483Y 30-mm guide 020512Y Piston fitting fork 020527Y Engine supporting base 020604Y011 Adaptor for fitting TOOL - 39...
Page 40 SCARABEO 500 Tooling Stores code Description AP8106702 Flywheel lock calliper spanner AP8140187 Engine supporting stand 020648Y Single battery charger 020661Y Water pump overall sealing re- placement kit TOOL - 40...
Page 41 INDEX OF TOPICS MAIN AINTENANCE...
Page 42: Maintenance Chart
SCARABEO 500 Maintenance Maintenance chart EVERY 2 YEARS Action coolant - replacement Brake fluid - change AFTER 1,000 KM Action Safety locks - check Throttle lever - adjustment Engine oil filter - replacement Electrical system and battery - check Coolant level - check Brake fluid level - check Engine oil - change Brake pads - condition and wear check...
Page 43 SCARABEO 500 Maintenance Action Spark plugs - replacement AFTER 15,000 KM; 45,000 KM; 75,000 KM Action Engine oil - level check/topping-up Brake pads - condition and wear check Centre stand - lubrication AFTER 20,000 KM; AFTER 40,000 KM; AFTER 60,000 KM AND AFTER 80,000 KM 190' Action Spark plugs - replacement...
Page 44: Spark Plug
SCARABEO 500 Maintenance Spark plug Check spark plugs according to the scheduled maintenance table. At regular intervals, remove spark plugs and clean off any carbon deposits or replace, if required. To access spark plugs remove the inspection cover as follows: •...
Page 45 SCARABEO 500 Maintenance • Disconnect the caps «3» of the high voltage cables from the spark plug. • Clean off any trace of dirt from the spark plug base by blowing com- pressed air. Unscrew the spark plugs and remove them from their seat, being careful not to let dust or any other sub- stance come into the cylinder.
Page 46 SCARABEO 500 Maintenance Characteristic Spark plug electrode gap 0.7 - 0.9 mm Locking torques (N*m) Spark plug 12 ÷ 14 Hub oil Check NOTE USE RECOMMENDED OIL ONLY. REFER TO THE RECOMMENDED PRODUCTS TABLE. • Ride a few kilometres until the regular working temperature is reached, then stop the engine. •...
Page 47 SCARABEO 500 Maintenance • Pour a little oil through the dipstick tube and wait one minute so that the oil flows evenly into the crankcase. • Top-up with small quantities of oil until the recommended level is reached. • Check hub oil level, top-up if necessary. •...
Page 48 SCARABEO 500 Maintenance • Pour the indicated quantity of recom- mended transmission oil through the fill opening. • Screw and tighten the measuring cap- dipstick «1». • Start the engine and let it run for sev- eral minutes. Stop the engine and let it cool down.
Page 49: Engine Oil
SCARABEO 500 Maintenance Engine oil In 4T engines, engine oil is used to lubricate the distribution elements, the bench bearings and the thermal group. In all 4T engines, a loss of efficiency in oil performance and some oil consumption should be considered normal, especially at the time of run-in.
Page 50 SCARABEO 500 Maintenance • Place a collecting container with +1700 cm³ (103.74 cu.in) capacity under the drainage plug «3». • Unscrew and remove the oil drainage plug «3» and then drain all the engine oil into the collecting container. • Fit a new engine oil cartridge filter and take special care to lubricate the filter sealing O-rings with oil.
Page 51 SCARABEO 500 Maintenance Check NOTE USE RECOMMENDED OIL ONLY. REFER TO THE RECOMMENDED PRODUCTS TABLE. CAUTION PARK THE VEHICLE ON SAFE AND LEVEL GROUND. • Rest the vehicle on its centre stand. CAUTION WAIT SOME MINUTES UNTIL THE ENGINE AND THE EXHAUST SYSTEM ARE COLD. •...
Page 52: Engine Oil Filter
SCARABEO 500 Maintenance TOP-UP • Pour a small quantity of oil through the tube «2» and wait approximately five minutes so that the oil flows evenly into the crankshaft. • Top-up with small quantities of oil, until the recommended level is reached. •...
Page 53: Cooling System
SCARABEO 500 Maintenance • Remove and clean the mesh pre-filter of the drainage plug «2» with com- pressed air. • With a strap-type oil filter wrench to re- move the cartridge filter «3». • Make sure the O-rings of the pre-filter and the drainage plug are in good con- ditions.
Page 54 SCARABEO 500 Maintenance PARK THE VEHICLE ON SAFE AND LEVEL GROUND. • Remove the front central cover. • Loosen (by turning it clockwise) but do not remove the filler cap «1». • Wait for some seconds so that any pressure could be purged. •...
Page 55: Braking System
SCARABEO 500 Maintenance WHEN TOPPING-UP, DO NOT EXCEED THE «MAX» LEVEL OR THE FLUID WILL FLOW OUT WHEN THE ENGINE IS RUNNING. • Refit the filler cap «1». • Refit the central cover. CAUTION IF THERE IS AN EXCESSIVE CONSUMPTION OF COOLANT OR WHEN THE EXPANSION TANK IS EMPTY, CHECK THAT THERE ARE NO LEAKS IN THE CIRCUIT.
Page 56 SCARABEO 500 Maintenance To check level: • Rest the vehicle on its centre stand. • Turn the handlebar so that the fluid in the brake fluid reservoir is parallel to the «MIN» reference mark indicated on the sight glass «1». •...
Page 57 SCARABEO 500 Maintenance • Undo the two screws «2» and the shorter screw «3». • To remove the lower and upper pump covers release them from their retain- ers. • Undo the 4 screws «4». CAUTION RISK OF BRAKE FLUID SPILLS. DO NOT PULL THE BRAKE LEVER WHEN THE SCREWS ARE LOOSE OR, MAINLY, WHEN THE BRAKE FLUID RESERVOIR COVER HAS...
Page 58 SCARABEO 500 Maintenance • Remove the pump cover with its gasket and top-up the reservoir only with rec- ommended fluid. Recommended products AGIP BRAKE 4 Brake fluid FMVSS DOT 4 Synthetic fluid System check To carry out a quick pad check: •...
Page 59 SCARABEO 500 Maintenance • In case of uneven wear, replace the pads when there is a thickness differ- ence of 0.5 mm in the friction material. CAUTION ALWAYS REPLACE BOTH PADS AND MAKE SURE THEY ARE CORRECTLY POSITIONED INSIDE THE CALLIPER. Dashboard Turning the ignition key to "ON"...
Page 60 SCARABEO 500 Maintenance Initial Status When switched on, the instrument panel shows the last function selected. DIGITAL ODOMETER These are the segments of the digital odometer functions on the LCD display: Icon to display trip odometer, six digits «4», icon showing unit of measure in km «5», icon showing unit of measure in miles «6».
Page 61 SCARABEO 500 Maintenance This warning light has a blue LED and must be on when the high-beam light is activated. This warning light has a red LED and signals there is an engine control unit failure. External antitheft device This warning light has a red LED and it is controlled by an external antitheft device (it is therefore not managed by the microprocessor).
Page 62: Headlight Adjustment
SCARABEO 500 Maintenance ignition check, 300 km to the next service. Once the mileage for the service has been reached, the icon will be steadily on until the Service is reset. Reset service To reset the service, press and hold down the MODE button «1»...
Page 63 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
Page 64 SCARABEO 500 Electrical system Components arrangement ELE SYS - 64...
Page 65 SCARABEO 500 Electrical system 1. INJECTION ELECTRONIC CONTROL UNIT Location: on the throttle body. Remove the helmet compartment to reach it. Connector location: on the component. 2. MAIN FUSES Location: under the specific battery cover placed in the helmet compartment. 3.
Page 66 SCARABEO 500 Electrical system 5. DIAGNOSTICS SOCKET Location: under the battery cover placed in the helmet compartment. 6. INSTRUMENT PANEL DIAGNOSTICS SOCK- Location: under the battery cover placed in the helmet compartment. 7. INSTRUMENT PANEL Connector location: on the component. 8.
Page 67 SCARABEO 500 Electrical system 9. SPEED SENSOR Location: on the front wheel right side. Connector location: under the legshield, near the horn. 10. FAN Location: at the front part of the vehicle, on the ra- diator. Remove the shield back plate to reach it. Connector location: under the central cover, near the fuel level sensor.
Page 68 SCARABEO 500 Electrical system 13. STARTER MOTOR Connector location: on the engine, near the throttle body. 14. VOLTAGE REGULATOR Location: at the front part of the vehicle, near the component supporting plate. Remove the leg- shield to reach it. Connector location: under the central cover, near the fuel pump.
Page 69 SCARABEO 500 Electrical system 17. FALL SENSOR Location: at the front part of the vehicle, on the component supporting plate. Remove the leg- shield to reach it. Connector location: near the component. 18. ANTITHEFT CONTROL UNIT Location: at the front part of the vehicle, near the key switch.
Page 70 SCARABEO 500 Electrical system 21. PICK-UP Connector location: under the central cover, near the fuel pump. 22. GLOVE-BOX ELECTRIC LOCK Location: on the vehicle left fairing, fixed to the helmet compartment. Remove the tail section to reach it. Connector location: on the component. 23.
Page 71 SCARABEO 500 Electrical system 25. HV COIL Location: at the bottom on the vehicle left fairing, near the side stand. Remove the left footrest to reach it. Connector location: on the component. 26. FUEL LEVEL SENSOR Location: on the fuel tank. Remove the central cover to reach it.
Page 72 SCARABEO 500 Electrical system Electrical system installation Front side MAIN CABLE HARNESS FITTING 1. 180x4.5 Clamp 2. 290x4.5 Clamp 3. 290x4.5 Clamp (holds the Main Cable Harness and Flywheel cables). 4. Attach the chassis retainer (already on the cable harness). 5.
Page 73 SCARABEO 500 Electrical system 1. Do not use any clamps 2. 290x4.5 Clamp ELE SYS - 73...
Page 74 SCARABEO 500 Electrical system 1. 290x4.5 Clamp 2. Attach the chassis retainer (already on the cable harness). 3.290x4.5 Clamp 4. 290x4.5 Clamp 5. 290x4.5 Clamp (do not pull with force). 6. 98x2.5 Clamp ELE SYS - 74...
Page 75 SCARABEO 500 Electrical system 1. 98x2.5 Clamp 2. 290x4.5 Clamp 1. 290x4.5 Clamp (holds the Main Cable Harness and Flywheel cables). ELE SYS - 75...
Page 76 SCARABEO 500 Electrical system 2. 180x4.5 Clamp 3. 290x4.5 Clamp (do not pull with force). 1. Cable guide plus a clamp 2. 290x4.5 Clamp ELE SYS - 76...
Page 77 SCARABEO 500 Electrical system 1. Cable guide plus a clamp 2. 98x2.5 Clamp ELE SYS - 77...
Page 78 SCARABEO 500 Electrical system 1. 98x2.5 Clamp 2. 98x2.5 Clamp 3. 98x2.5 Clamp ELE SYS - 78...
Page 79 SCARABEO 500 Electrical system 1. Start-up relay fitted on the rubber ring 2. Cable guide plus a clamp 3. 98x2.5 Clamp 1. 180x4.5 Clamp 2. 180x4.5 Clamp 3. 98x2.5 Clamp 4. 98x2.5 Clamp RIGHT LIGHT SWITCH ELE SYS - 79...
Page 80 SCARABEO 500 Electrical system 1. 98x2.5 Clamp LEFT LIGHT SWITCH 1. 98x2.5 Clamp ELE SYS - 80...
Page 81 SCARABEO 500 Electrical system SPEED SENSOR FITTING 1. 98x2.5 Clamp 2. 98x2.5 Clamp 3. 98x2.5 Clamp ELE SYS - 81...
Page 82 SCARABEO 500 Electrical system 1. Speed Sensor Connection 2. 98x2.5 Clamp Back side MAIN CABLE HARNESS FITTING ELE SYS - 82...
Page 83 SCARABEO 500 Electrical system KEY: 1. 290 x 4.5 Clamp 2. Metal clamp 3. LAMBDA Probe connector 4. 180 x 4.5 Clamp 5. Cable guide 6. The cable harness must be under the cable guide 7. 290 x 4.5 Clamp ELE SYS - 83...
Page 84 SCARABEO 500 Electrical system KEY: 1. The cable harness must be under the cable guide 2. 290 x 4.5 Clamp 3. 180 x 4.5 Clamp 4. 290 x 4.5 Clamp ELE SYS - 84...
Page 85 SCARABEO 500 Electrical system KEY: 1. 290 x 4.5 Clamp 2. Cable guide 3. Metal bracket 4. The cable harness must be under the cable guide 5. 290 x 4.5 Clamp KEY: 1. 180 x 4.5 Clamp 2. 290 x 4.5 Clamp ELE SYS - 85...
Page 86 SCARABEO 500 Electrical system KEY: 1. 180 x 4.5 Clamp KEY: 1. Glove-box Light Connector 2. 180 x 4.5 Clamp ELE SYS - 86...
Page 87 SCARABEO 500 Electrical system KEY: 1. 180 x 4.5 Clamp 2. 290 x 4.5 Clamp 3. The cable harness must be under the cable guide 4. 290 x 4.5 Clamp ELE SYS - 87...
Page 88 SCARABEO 500 Electrical system KEY: 1. The cable harness must be under the cable guide 2. 290 x 4.5 Clamp 3. 290 x 4.5 Clamp 4. Start-up relay KEY: 1. 290 x 4.5 Clamp 2. 180 x 4.5 Clamp ELE SYS - 88...
Page 89 SCARABEO 500 Electrical system KEY: 1. Cable harness installation inside the Battery Compartment KEY: 1. Cable harness installation inside the Battery Compartment ELE SYS - 89...
Page 90 SCARABEO 500 Electrical system KEY: 1. The Oil Pressure Bulb cable is inside the specific cable guide fitted on the engine. 2. The Oil Pressure Bulb cable crosses behind the engine breather pipe. KEY: 1. Flywheel Cable output part ELE SYS - 90...
Page 91 SCARABEO 500 Electrical system KEY: 1. 98 x 2.5 Clamp 2. LAMBDA probe 3. 290 x 4.5 Clamp CHASSIS - ENGINE GROUND LEAD FITTING ELE SYS - 91...
Page 92 SCARABEO 500 Electrical system KEY: 1. Screw 2. Screw START-UP RELAY - STARTER MOTOR CABLE FITTING KEY: 1. 290 x 4.5 Clamp ELE SYS - 92...
Page 93 SCARABEO 500 Electrical system KEY: 1. 290 x 4.5 Clamp 2. Cable guide LICENSE PLATE LIGHT CABLE HARNESS FITTING KEY: ELE SYS - 93...
Page 94 SCARABEO 500 Electrical system 1. 180 x 4.5 Clamp 2. 180 x 4.5 Clamp KEY: 1. 180 x 4.5 Clamp 2. License Plate Light Connector Checks and inspections Battery recharge circuit The recharge system consists of a three-phase generator with a permanent magneto flywheel. The generator is directly connected to the voltage regulator.
Page 95 SCARABEO 500 Electrical system 1) Remove the central cover. 2) Disconnect the connector between the stator and the regulator located near the fuel pump. 3) Measure the resistance between each yellow terminal and the other two. Electric characteristic Resistance: 0.2 ÷ 1 4) Check that there is insulation between each yel- low cable and the ground lead.
Page 96 SCARABEO 500 Electrical system Voltage between 14.0 and 15.0 V at 5000 rpm. Finding possible leaks 1) Access the battery by removing the corresponding cover under the saddle. 2) Before checking the output voltage, check that the battery does not show fluid leaks. 3) Turn OFF the ignition key, connect the multimeter probes between the battery negative (-) pole and the Black cable and only then disconnect the Black cable from the battery negative (-) pole.
Page 97 SCARABEO 500 Electrical system • Check that the Black cable between the light switch and the low-beam light bulb is not in- terrupted. • Check that the White cable between the light switch and the high-beam light bulb is not interrupted.
Page 98 SCARABEO 500 Electrical system Specification Desc./Quantity Fuse C Capacity: 15 A Protected circuits: Instrument panel, horn, tail lights, high-beam light, low-beam light. Fuse D Capacity: 10A Protected circuits: Lighting and electronic lock of the helmet compartment, antitheft de- vice control unit. Fuse E Capacity: 10A Protected circuits: fan, injection ECU.
Page 99 SCARABEO 500 Electrical system 1. Voltage check • Before installing the battery on the vehicle, check the open circuit voltage with a regular multimeter. • If voltage is over 12.60V, the battery can be installed without any refresh. • If voltage is below 12.60 V, a refresh recharge is required as explained in point 2). 3.
Page 100 SCARABEO 500 Electrical system density is about 1.27, corresponding to 31º Bé, and these values are stabi- lised. • Once the charge is over, level the acid (by adding distilled water). Close and clean carefully. • Once the above operations have been performed, install the battery on the ve- hicle making sure that it is properly wired up.
Page 101 SCARABEO 500 Electrical system nominal capacity). Connections to the power supply source must be implemented by connecting cor- responding poles (+ to + and - to -). The battery should always be kept clean, especially its top side, and the terminals should be coated with petroleum jelly.
Page 102 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
Page 103 SCARABEO 500 Engine from vehicle Exhaust assy. Removal • Loosen the clamp of the exhaust mani- fold. • Undo and remove the screw fixing the exhaust end sealing clamp. • Push in the exhaust and remove the upper pin fixing the sealing clamp. •...
Page 104 SCARABEO 500 Engine from vehicle • Remove the tail section. • Disconnect the lambda probe connec- tor. • Unscrew the two nuts fixing it to the head. • Remove the manifold with the gasket. Removal of the engine from the vehicle •...
Page 105 SCARABEO 500 Engine from vehicle • Slide off the pipe. • Drain off the system. NOTE REMOVE THE EXPANSION TANK CAP TO FA- CILITATE COOLANT DRAINAGE. • Working on the right side of the vehicle, undo and remove the two side screws fixing the rear mudguard;...
Page 106 SCARABEO 500 Engine from vehicle • Undo and remove the screw fixing the oil scavenge flange. • Slide the flange off its seat. • Undo the screw of the air filter internal support. • Loosen the intake manifold clamp. • Remove the clamp indicated.
Page 107 SCARABEO 500 Engine from vehicle • Slide off the bleed pipe. • Remove the filter housing. • Prepare the hoist and secure the motor vehicle properly with the hoisting belt. • Undo and remove the upper screw fix- ing the right shock absorber and collect the nut.
Page 108 SCARABEO 500 Engine from vehicle • Detach the shock absorber. • Undo the lower screw fixing the rear left shock absorber and collect the nut. • Detach the shock absorber. • Loosen the set screws and slide off the throttle control cables. ENG VE - 108...
Page 109: Fuel Pipe Fixing Screw
SCARABEO 500 Engine from vehicle • Loosen the clamp of the thermostatic valve. • Disconnect the pipes. NOTE USE A CONTAINER OF ADEQUATE CAPACITY TO COLLECT THE FLUID THAT MAY LEAK DURING OPERATION. • Remove the spark plug tubes. • Remove the injector control sensor.
Page 110 SCARABEO 500 Engine from vehicle • Disconnect the coolant temperature sensor. • Disconnect the lambda probe connec- tor. • Release the cables from the cable guide clamp. • Disconnect the MIU control unit con- nector and remove the fixing screw from the retainer clamp.
Page 111 SCARABEO 500 Engine from vehicle • Disconnect the oil pressure sensor. • Working on both sides, undo and re- move the side screw fixing the chassis central cover. • Slightly lift the chassis central cover. • Disconnect the voltage regulator con- nector and the revolution sensor con- nector.
Page 112 SCARABEO 500 Engine from vehicle • Loosen the clamp of the exhaust mani- fold. • Undo and remove the screw fixing the exhaust end sealing clamp. • Push in the exhaust and remove the upper pin fixing the sealing clamp. •...
Page 113 SCARABEO 500 Engine from vehicle • Remove the cap. • With the help of a second operator, op- erate the rear brake; unscrew and re- move the rear nut fixing the muffler supporting bracket. • Unscrew and remove the two front nuts fixing the muffler supporting plate.
Page 114 SCARABEO 500 Engine from vehicle • Remove the muffler supporting plate. • Remove the spacer. • Undo and remove the five screws fixing the wheel. • Remove the wheel. NOTE PLACE AN ADEQUATE SUPPORT AT THE LOWER PART OF THE MOTOR VEHICLE. •...
Page 115 SCARABEO 500 Engine from vehicle • Move the protection casing. • Unscrew and remove the positive lead fixing nut. • Release the positive lead. • Working on the right side, unscrew the nut fixing the swinging arm pin and col- lect the washer.
Page 116 SCARABEO 500 Engine from vehicle • Unscrew the pin and collect the wash- • The engine is now free. • Upon refitting the engine onto the vehicle, carry out the removal operations but in reverse order, observing the tightening torques shown in the «Specifications» Chapter. •...
Page 117 INDEX OF TOPICS NGINE...
Page 118: Automatic Transmission
SCARABEO 500 Engine This section describes the operations to be carried out on the engine and the tools required. Automatic transmission Transmission cover - Undo the 4 fixing screws. - Take out the plastic external transmission cover. - Using a screwdriver, remove the driven pulley axis cover by acting on the bottom of the cap.
Page 119 SCARABEO 500 Engine - Remove the six M6 screws. - Remove the four M8 screws. - Remove the transmission cover. - Check that the bearing rotates freely; otherwise, replace it. Air duct - Remove the transmission cover. - To remove the air deflector, undo the two screws indicated in the figure.
Page 120 SCARABEO 500 Engine Air duct filter - Remove the external air deflector. - Undo the 2 fixing screws indicated in the figure to remove the deflector filter. Removing the driven pulley shaft bearing - Remove the transmission cover. - Remove the Seeger ring. - Place the transmission cover on a wooden sur- face and use the specific tool so that it is ade- quately supported.
Page 121 SCARABEO 500 Engine Refitting the driven pulley shaft bearing - Heat the internal side of the transmission cover with a heat gun. NOTE BE CAREFUL NOT TO OVERHEAT THE COV- ER AS THIS WOULD DAMAGE THE EXTERNAL PAINTED SURFACE. Specific tooling 020151Y Air heater 020150Y Air heater support - Fit the bearing onto the specific tool with a little...
Page 122: Char
SCARABEO 500 Engine Anti-flapping roller screw 16.7 ÷ 19.6 Removing the driven pulley - Slide off the clutch bell. - Remove the fixed driving half-pulley. - Slide off the driven pulley unit together with the belt. Inspecting the clutch drum - Make sure that the clutch bell is not worn or dam- aged.
Page 123: Removing The Clutch
SCARABEO 500 Engine - The masses must not show traces of lubricants. If they do, check the driven pulley unit seals. NOTE UPON RUNNING-IN, THE MASSES MUST EXHIBIT A CENTRAL FAYING SURFACE AND MUST NOT BE DIFFERENT FROM ONE ANOTHER. DIFFERENT CONDITIONS MAY CAUSE CLUTCH TEARING.
Page 124 SCARABEO 500 Engine Pin retaining collar - Slide off the collar with the aid of 2 screwdrivers. - Remove the 4 guide pins. - Slide off the movable driven half-pulley. Removing the driven half-pulley bearing - Check there are no signs of wear or damage on the bushing;...
Page 125: Char
SCARABEO 500 Engine TO SERVICE THE BEARINGS ON A FITTED DRIVEN PULLEY UNIT, SUPPORT THE UNIT BY THE BELL. Specific tooling 001467Y002 Driver for bearing with OD 73 mm - Remove the roller bearing with the specific tool, supporting the fixed half-pulley with the bell. Specific tooling 020376Y Adaptor handle 020375Y 28 x30 mm Punch...
Page 126 SCARABEO 500 Engine Refitting the driven half-pulley bearing - Fit a new roller bearing with the specific tool. NOTE PLACE THE BEARING WITH THE WORDS AND THE BUILT-IN OIL SEAL FACING OUTWARDS. - Properly support the half-pulley to prevent damaging the threading. If you are working on the driven pulley assembly fully fitted, use the specific tool.
Page 127: Char
SCARABEO 500 Engine - Fit the half-pulley on the bushing being careful not to damage the top sealing ring. - Make sure the pins and collar are not worn and refit the pins and the collar. - Using a curved-spout grease gun, lubricate the driven pulley assembly with approximately 10 grams of grease.
Page 128 SCARABEO 500 Engine NOTE BE CAREFUL NOT TO DAMAGE THE SHEATH OR THE BUSHING THREADED END. - Finger tighten the ring nut and complete the tight- ening to the prescribed torque using the appropri- ate spanner. Specific tooling AP8140259 Tool for fitting/removing the clutch on the driven pulley Locking torques (N*m) Clutch ring nut 65 - 75...
Page 129 SCARABEO 500 Engine Removing the driving pulley - Using a 27-mm spanner, turn the pulley central nut to align the central internal holes horizontally and to fit the specific tool. Specific tooling 020474Y Driving pulley lock wrench - First fit the 2 retainer clamps of the specific tool into the pulley so that the spline is fully engaged.
Page 130 SCARABEO 500 Engine - Measure the outside diameter of the pulley sliding bushing shown in the figure. Characteristic Minimum diameter allowed: Ø 29.95 mm Standard diameter: Ø 29.959 mm - Check that the rollers are not damaged or worn. Characteristic Minimum diameter allowed: Ø...
Page 131 SCARABEO 500 Engine Refitting the driving pulley Roller container fitting - Fit the spacer with the internal chamfered side facing the fitting side. - Place the rollers in the half-pulley as shown in the figure. - The closed side must rest on the internal thrust side of the roller container.
Page 132 SCARABEO 500 Engine Fixed driving half-pulley fitting - Fit the spacer. - Fit the fixed driving half-pulley and check that it is in contact with the spacer and with the guide bushing of the movable driving pulley. - Fit the plain and the belleville washers as shown in the figure.
Page 133 SCARABEO 500 Engine - Turn the pulley central nut so that the pulley holes are aligned horizontally to fit the specific tool. NOTE CHECK THAT THE LOCK WRENCH TOOL CAN BE EASILY FITTED INTO THE PULLEY AND IN THE ENGINE CRANKCASE. Specific tooling 020474Y Driving pulley lock wrench - Fit the retainer clamp from the rear, so that the...
Page 134 SCARABEO 500 Engine - Lock the 7 M6 retainers. Locking torques (N*m) M6 Retainer 11 ÷ 13 - Fit the washers on the driven pulley shaft. NOTE FIT THE WASHER WITH THE SMALLER OUTSIDE DIAMETER FIRST, THEN THE LARGER ONE. - Insert the flanged nut.
Page 135 SCARABEO 500 Engine - Fit the plastic external transmission cover. - Tighten the 4 fixing screws to the prescribed tor- que. Locking torques (N*m) External transmission cover screws 7 ÷ 9 End gear Removing the hub cover - Drain the rear hub oil through the oil drainage plug located under the engine.
Page 136 SCARABEO 500 Engine Removing the hub bearings - Check all bearings for correct conditions (wear, clearance and noise). If any fault is detected, proceed as follows. To remove the wheel axle bearing on the engine crankcase, use the following parts. Specific tooling 001467Y014 Pliers to extract Ø...
Page 137 SCARABEO 500 Engine Removing the wheel axle bearings - Remove the Seeger ring from the outside of the hub cover. - Support the hub cover using the stud bolt set. - Extract the bearing with the specific tool. Specific tooling 020476Y Stud bolt set 020376Y Adaptor handle 020477Y 37-mm adaptor...
Page 138 SCARABEO 500 Engine - Remove the driven pulley shaft bearing from the engine crankcase using a specific tool. Specific tooling 020376Y Adaptor handle 020358Y 37 x 40 mm adaptor 020364Y 25-mm guide Inspecting the hub shaft - Check the 3 shafts for wear or distortions on the toothed surfaces, on the bearing housings and the oil seals.
Page 139 SCARABEO 500 Engine B = Ø 30 - 0.010 -0.023 mm C = Ø 15 - 0.01 -0.02 mm Bearing diameter for driven pulley shaft: D = Ø 17 - 0.01 -0.02 mm E = Ø 20 - 0.01 -0.02 mm F = Ø...
Page 140 SCARABEO 500 Engine - Heat the intermediate gear bearing seat. - Fit the intermediate shaft bearing using the spe- cific tool. NOTE PLACE IT WITH THE BALLS FACING THE HUB SIDE (THIS APPLIES TO BEARINGS WITH PLASTIC CAGE). Specific tooling 020376Y Adaptor handle 020359Y 42 x 47 mm adaptor 020363Y 20-mm Oil seal guide...
Page 141 SCARABEO 500 Engine - Heat the crankcase with an air heater. Specific tooling 020151Y Air heater 020150Y Air heater support - Using the specific tool fit the driven pulley shaft bearing until it stops against the bottom of the seat. NOTE PLACE IT WITH THE BALLS FACING THE HUB SIDE (THIS APPLIES TO BEARINGS WITH...
Page 142 SCARABEO 500 Engine 020359Y 42 x 47 mm adaptor 020412Y 15-mm guide - Place the safety Seeger ring locking the driven pulley shaft bearing. NOTE PLACE IT IN THE POSITION SHOWN IN THE FIGURE. - Fit the pulley shaft oil seal on the transmission side.
Page 143 SCARABEO 500 Engine 020363Y 20-mm Oil seal guide - Heat the wheel axle bearing seat from the cover external side. - Fit the wheel axle bearing on the cover until it stops using the specific punch. Specific tooling 020376Y Adaptor handle 020360Y 52 x 55 mm adaptor 020483Y 30-mm guide - Refit the circlip.
Page 144 SCARABEO 500 Engine Flywheel cover - Remove the three clamps shown in the figure for an easy removal of the flywheel cover, remove the cylinder feed coupling and disconnect the return coupling from the pump cover NOTE THE CLAMPS MUST BE REPLACED. TO RE- MOVE THEM, OPEN OR CUT THEM USING A SCREWDRIVER.
Page 145 SCARABEO 500 Engine - Undo the 14 fixing screws. - Remove the flywheel cover with the relevant gas- ket and the support of the cooling system sleeves. NOTE THE SCREWS COME IN 4 DIFFERENT LENGTHS, NOTE THEIR POSITIONS. CAUTION REMOVE THE COVER AVOIDING ANY POSSIBLE INTERFERENCE BETWEEN STATOR AND ROTOR.
Page 146 SCARABEO 500 Engine Removing the stator - Remove the 2 fixing screws and the cable har- ness guide bracket. - Undo the 3 fixing screws and remove the stator with the cable harness. Inspecting the cover components - Undo the 2 fixing screws and remove the reed valve support with bulkhead.
Page 147 SCARABEO 500 Engine - Undo the fixing screw and remove the gas outlet union with the relevant O-ring. - Check that the crankcase coupling surface is not worn or distorted. - Check that the by-pass valve seat, the torque limiter bearing and the water pump shaft bearing are not worn.
Page 148 SCARABEO 500 Engine - Check the continuity between the 3 phases. NOTE THE VALUES ARE STATED AT AMBIENT TEM- PERATURE. A CHECK WITH THE STATOR AT OPERATING TEMPERATURE MAY RESULT IN VALUES HIGHER THAN THOSE STATED. Electric characteristic Resistance: 0.2 ÷ 1 - Check the earth insulation of each phase.
Page 149 SCARABEO 500 Engine - Fit the guide bracket with the cable harness, fix- ing the 2 screws to the prescribed torque. Locking torques (N*m) Stator cable harness guide bracket screws 3 - Refitting the flywheel cover components - Before refitting, check that all components are perfectly clean.
Page 150 SCARABEO 500 Engine - Temporarily fit the plug for the distribution timing check hole and the engine oil filler cap/dipstick. - Fit the blow-by recovery duct using a new O-ring. - Tighten the screw to the prescribed torque. Locking torques (N*m) Blow-by scavenge duct fixing screws 3 - 4 - Fit the spring and the by-pass piston on the fly- wheel cover.
Page 151 SCARABEO 500 Engine - Temporarily fit the plug for the distribution timing check hole and the engine oil filler cap/dipstick. - Fit the blow-by recovery duct using a new O-ring. - Tighten the screw to the prescribed torque. Locking torques (N*m) Blow-by scavenge duct fixing screws 3 - 4 - Fit the spring and the by-pass piston on the fly- wheel cover.
Page 152 SCARABEO 500 Engine - Refit the blow-by reed valve and use a new seal- ing gasket. - Refit the support with bulkhead by tightening the screws to the prescribed torque. Locking torques (N*m) Supporting screws with bulkhead 0.3 ÷ 0.4 Refitting the flywheel cover - Fit a new oil filter, lubricate the sealing gasket, draw it close and finally tighten to the prescribed...
Page 153 SCARABEO 500 Engine - Lubricate the seat of the intermediate gear with the torque limiter on the flywheel cover. - Align the water pump drive with a reference and fit the flywheel cover as described in the Flywheel cover chapter. - Fit a new gasket on the engine crankcase.
Page 154 SCARABEO 500 Engine - Fix the 14 cover fixing screws and tighten them to the prescribed torque. NOTE THE SCREWS COME IN FOUR DIFFERENT LENGTHS: - THE 3 SHORTEST ARE FITTED AS SHOWN IN THE FIGURE. - THE LONGEST IS FITTED UNDER THE EN- GINE OIL FILLER PLUG.
Page 155 SCARABEO 500 Engine 2 - Check the correct connection of the negative terminals (battery negative and starter motor neg- ative), between them and to the chassis. YES go to point 4 NO go to point 5 3 - Recharge and, if necessary, replace the battery. 4 - Connect the diagnostic tester (see the «injection»...
Page 156 SCARABEO 500 Engine < 40 A YES go to point 10 NO go to point 11 7 - Low driving speed High electrical absorption Check for engine rotation (example: possible bushing jamming) and if no faults are detected, replace the starter motor. 8 - Low driving speed Low electrical absorption Repeat the test, bridging the power terminals of the start-up remote control switch or rather replacing...
Page 157 SCARABEO 500 Engine The start-up system has a gear between the motor armature and the crankshaft that is equipped with a freewheel coaxial to the flywheel and the torque limiter on the intermediate shaft. The torque limiter is calibrated at 10 kgm (100 Nm); this component protects the structure of the engine and the start-up kinematic mechanism in the event of incorrect start-up procedure, resulting in inverse rotation.
Page 158 SCARABEO 500 Engine - Align the two holes on the flywheel with the seat on the crankcase so that the specific tool can be placed. - Tighten the bushing which is part of the flywheel locking tool on the extractor thread. - Fit the specific tool as shown in the figure, making sure that the pins are perfectly inserted into the previously aligned holes and that they are fitted...
Page 159 SCARABEO 500 Engine - Remove the washer. - Insert the nut again so as to slightly uncover the shaft and free the space previously occupied by the washer. CAUTION THIS OPERATION IS REQUIRED AS THE FLY- WHEEL IS STRONGLY LOCKED; IF THE CONE GETS DETACHED, THIS MAY CAUSE THE RO- TOR TO FALL, AND CONSEQUENTLY THE MAGNETS MAY BREAK.
Page 160 SCARABEO 500 Engine - To remove the starting ring gear from the free- wheel, turn it clockwise and slide off. - Remove the freewheel from the magneto fly- wheel by undoing the 6 fixing screws. SHOULD THE FREEWHEEL NEED TO BE RE- MOVED, IT IS ADVISABLE TO LOOSEN THE 6 FIXING SCREWS IN ADVANCE, WITH THE FLY- WHEEL STILL FITTED ON THE CRANKSHAFT.
Page 161 SCARABEO 500 Engine Inspecting the flywheel components - Check that the magnets are in good conditions. - Check that the magnet support cage is not de- formed or broken. Starter gear rim - Check that there is no wear or abnormal marks on the «rollers»...
Page 162 SCARABEO 500 Engine Intermediate gear - Check that the toothing is not worn. - Check the diameter of the two bearings. Characteristic Gear bearing diameter 12 (0; - 0.011) mm (0.47000 (0; -0.00043) in) Also check the diameter of the bearings on the fly- wheel cover and on the engine crankcase.
Page 163 SCARABEO 500 Engine Recommended products Loctite 243 Medium strength threadlock - Fit the freewheel on the magneto flywheel, mak- ing sure that the ground side is in contact with the flywheel, that is the wheel Seeger ring should be visible. - Tighten the 6 fixing screws in a criss-cross se- quence to the prescribed torque.
Page 164 SCARABEO 500 Engine - Fit the intermediate gear with torque limiter. - Lubricate the internal bushing and the starter ring gear hub surface. - Fit the starting ring gear on the flywheel by turning it clockwise and inserting the gear at the same time.
Page 165 SCARABEO 500 Engine - Fit the washer and the nut on the crankshaft. - Tighten the guide bushing which is part of the flywheel locking tool as far as it will go and then loosen it 1/4 of a turn. NOTE FAILURE TO OBSERVE THIS RULE CAUSES THE GUIDE ON THE FLYWHEEL TO GET...
Page 166 SCARABEO 500 Engine - Tighten the flywheel lock nut to the prescribed torque. Locking torques (N*m) Flywheel fixing nut 115 - 125 - Fit the chain guide slider retention plate by tight- ening the 3 screws to the prescribed torque. NOTE BEFORE TIGHTENING THE SCREWS, MOVE THE STARTING RING GEAR UNTIL IT MAKES...
Page 167 SCARABEO 500 Engine - Remove the flywheel cover, the flywheel and the torque limiter. Removing the intake manifold - Undo the 3 fixing screws. - Remove the complete inlet manifold unit. Removing the rocker-arms cover - Undo the 6 special screws with stop and the rel- evant rubber gaskets.
Page 168 SCARABEO 500 Engine Removing the timing system drive - Turn the engine until the intake valves are closed. - Remove the central screw and the valve-lifter mass retaining cover using the specific tool. Specific tooling AP8106702 Flywheel lock calliper spanner - Remove the return spring and the valve-lifter mass with relevant end of stroke washer.
Page 169 SCARABEO 500 Engine - Loosen the central screw on the tensioner first. - Remove the 2 fixing screws and remove the ten- sioner with the relevant gasket. Remove the internal hex screw and the counter- weight as shown in the figure. - Remove the timing chain gear from the camshaft.
Page 170: Removing The Cylinder Head
SCARABEO 500 Engine - Remove the camshaft. CAUTION THE TWO CAMSHAFTS ARE DIFFERENT ONE FROM THE OTHER. IT IS POSSIBLE TO IDEN- TIFY THEM BY LETTER "A" (FRONT) OR "P" (REAR) STAMPED ON THE EXTERNAL SHOULDER, CROWN GEAR SIDE. - Remove the pins and the rocking levers acting from the transmission-side holes.
Page 171 SCARABEO 500 Engine - Remove the 2 fixing nuts on the head, outlet and intake sides. - Remove the two M6 side clamps inside the dis- tribution channel and the M6 side clamp, spark- plug side, together with the thermostat support. NOTE IF NECESSARY, THE HEAD MAY BE REMOVED TOGETHER WITH THE CAMSHAFT, ROCKING LEVER PINS AND MOUNTING BRACKET.
Page 172: Removing The Valves
SCARABEO 500 Engine Removing the valves - Using the appropriate tool fitted with an adapter, remove the cotter pins, plates, springs and valves. Specific tooling AP0276474 Valve spring compressor adaptor CAUTION ARRANGE THE VALVES SO AS TO RECOGNISE THEIR ORIGINAL POSITION ON THE HEAD (FLYWHEEL-SIDE AND TRANSMISSION-SIDE).
Page 173 SCARABEO 500 Engine Removing the cylinder - piston assy. - Remove the timing chain. - Undo the fixing screw and remove the spacer and the tensioner slider. NOTE IT IS ADVISABLE TO MARK THE CHAIN IN OR- DER TO ENSURE THAT THE INITIAL DIREC- TION OF ROTATION IS MAINTAINED.
Page 174 SCARABEO 500 Engine Inspecting the small end - Measure the inside diameter of the rod small end using a bore meter. NOTE IF THE ROD SMALL END DIAMETER EXCEEDS THE STANDARD DIAMETER, SHOWS SIGNS OF WEAR OR OVERHEATING, REPLACE THE CRANKSHAFT AS DESCRIBED IN THE «CRANKCASE AND CRANKSHAFT»...
Page 175 SCARABEO 500 Engine NOTE THE PIN HOUSINGS HAVE TWO LUBRICATION CHANNELS FOR THIS REASON MEASURE THE DIAMETER ACCORDING TO THE PISTON AXIS Characteristic Standard clearance: 0.001 ÷ 0.010 mm - Measure the piston outside diameter, perpendic- ular to the pin axis. - Carry out the measurement according to the po- sition shown in the figure: NOTE...
Page 176 SCARABEO 500 Engine - Pistons and cylinders are classified according to their diameter. This coupling is carried out in pairs (A-A, B-B, C-C, D-D). NOTE TO MEASURE THE CYLINDER AND THE CYLINDER-PISTON COUPLING CLEARANCE REFER TO THE «SPECIFICATIONS» SECTION. Inspecting the piston rings - Alternately fit the 3 sealing rings in the cylinder in the area where it keeps its original diameter.
Page 177: Removing The Piston
SCARABEO 500 Engine Maximum clearances allowed after use: 0.10 If clearances measured exceed the maximum val- ues specified in the table, the piston should be replaced with a new one. Removing the piston - Install piston and pin onto the connecting rod, with the piston arrow aligned facing the exhaust.
Page 178 SCARABEO 500 Engine - Fit the pin snap ring with the pin as shown in the figure. Specific tooling 020470Y Pin snap ring fitting tool NOTE THE TOOL FOR INSTALLING THE STOP RINGS MUST BE USED MANUALLY. CAUTION USING A HAMMER MAY DAMAGE THE RINGS HOUSINGS. Choosing the gasket - First fit the piston into the cylinder, without any base gasket.
Page 179 SCARABEO 500 Engine NOTE IF DEVIATIONS (PROTRUSIONS OR RECESSES) CLOSE TO THE CHANGE OF CATEGORY ARE MEASURED, REPEAT THE MEASUREMENT AT THE OPPOSITE SIDE. TO DO SO, REPEAT THE TOOL FITTING OPERATION, INVERTING ITS POSITION. Characteristic Recess / Protrusion measured 1 - 0.185 ÷...
Page 180 SCARABEO 500 Engine Refitting the cylinder - Fit the cylinder base gasket of the chosen thick- ness. - With the fork support and the retaining clamp, fit the cylinder as shown in the figure. NOTE BEFORE FITTING THE CYLINDER, CAREFUL- LY BLOW AIR INTO THE LUBRICATION DUCT AND LUBRICATE THE CYLINDER LINER.
Page 181 SCARABEO 500 Engine Inspecting the timing system components - Check that the guide slider and the tensioner pad are not excessively worn. - Check that the timing system gear unit controlling the camshaft and the crankshaft pinion is not worn. - If signs of wear are found in the pads, replace them;...
Page 182 SCARABEO 500 Engine - Fit the valves into the cylinder head. - Alternatively test the intake and outlet valves. - The test should be carried out by filling the mani- fold with fuel and checking that the head does not ooze through the valves when they are just press- ed by the fingers.
Page 183 SCARABEO 500 Engine - Calculate the clearance between the valve and its guide. - Check the deviation of the valve stem by resting it on a « V »-shaped support and measuring the extent of the deformation using a dial gauge. Characteristic Limit value allowed: 0.1 mm...
Page 184 SCARABEO 500 Engine VALVE STANDARD LENGTH Specification Desc./Quantity Inlet: 95.0 ± 0.3 mm Outlet: 94.2 ± 0.3 mm - Check that there are no signs of wear on the fay- ing surface with the set screw articulated terminal. - If no anomalies are found during the above checks, the same valves can be reused.
Page 185 SCARABEO 500 Engine Inspecting the springs and half-cones - Check that the upper and lower supporting spring plates, the cotters and the oil seal show no sign of abnormal wear. Otherwise, replace the compo- nent. - Measure the unloaded spring length. Characteristic Standard length: 44.4 mm...
Page 186 SCARABEO 500 Engine DO NOT CHANGE THE VALVE FITTING POSITION. FIT THE VALVE SPRINGS WITH THE REF- ERENCE COLOUR ON THE COTTERS SIDE (TURNS WITH GREATER PITCH). - Place the valve spring supporting plates on the head. - Fit the 4 oil seals alternately with the specific tool. - Lubricate the oil seals and the valve guides.
Page 187 SCARABEO 500 Engine - Using a gauge, measure the height of the cams. STANDARD HEIGHT Specification Desc./Quantity inlet 33.774 mm outlet 33.273 LIMITS ALLOWED Specification Desc./Quantity inlet 33.526 mm outlet 33.026 mm Standard axial clearance: 0 ÷ 0.22 mm Maximum axial clearance allowed: 0.3 mm - If values measured are not within the specified limits or there are signs of excessive wear, replace...
Page 188 SCARABEO 500 Engine - Check there are no signs of wear on the auto- matic valve-lifter cam, the end-of-stroke roller and the rubber buffer on the automatic valve lifter re- taining cover. - Check that the automatic valve-lifter return spring is not deformed by over-stretching.
Page 189 SCARABEO 500 Engine - The head gasket is made of steel and has a standard thickness. - Check that the head lubrication channel is per- fectly clean. Clean with short blasts of compressed air, if required. - Fit the head. - Lubricate the screw studs and the 4 fixing stud bolts.
Page 190 SCARABEO 500 Engine - Tighten the 3 side screws to the prescribed tor- que. Locking torques (N*m) Head fixing screws 10 - 12 - Fit the coolant temperature sensor with the wash- er and tighten it to the prescribed torque. CAUTION FAILURE TO OBSERVE THE LOCKING TOR- QUE CAN DAMAGE THE SENSOR.
Page 191 SCARABEO 500 Engine - Clean the camshaft by blowing short blasts of compressed air, especially the groove that holds the retaining plate. - Lubricate the 2 bearings. - Fit the camshaft in the cylinder head with the cams opposing the rocking levers. - Remove any LOCTITE left on the screws fixing the camshaft retaining bracket using a brush.
Page 192 SCARABEO 500 Engine - Fit the chain on the camshaft control timing sys- tem gear. - Fit the timing system gear on the camshaft mak- ing sure that references are aligned. NOTE UPON CHECKING TIMING, KEEP THE CHAIN TAUTENED BY EXERTING PRESSURE FROM THE TIGHTENER COMPARTMENT.
Page 193 SCARABEO 500 Engine - Fit the return spring and load it by about 3/4 of a turn. - Turn the engine to move the references to the top as shown in the figure (intake end). - Fit the valve-lifter mass retainer cover. - Tighten the fixing screw to the prescribed torque, using the recommended product.
Page 194 SCARABEO 500 Engine - Place the tensioner slider at the rest position, keeping the retaining tab pressed. - Fit the chain tensioner on the cylinder, using a new gasket. - Tighten the two fixing screws to the prescribed torque. Locking torques (N*m) Tensioner fixing screws 11 ÷...
Page 195 SCARABEO 500 Engine - If different values are detected, adjust by loos- ening the lock nut and operating on the set screw with a screwdriver, as shown in the figure. Refitting the timing chain The ignition advance is determined electronically on the basis of parameters known by the control unit. For this reason it is not possible to state the reference values based on the engine revs.
Page 196 SCARABEO 500 Engine - Acting on the driving pulley nut, turn the engine until the references to determine the TDC are found. - Repeat for the reference between the driving pul- ley and the transmission cover - Connect the diagnostic tester. - Start the engine.
Page 197 SCARABEO 500 Engine Refitting the rocker-arms cover - Check that the gasket is in good condition. - Tighten the two screws indicated in the figure with «1» and «2» to limit the reciprocal sliding of the cover surface with the head surface. - Tighten the remaining 4 screws in a criss-crossed sequence (3,4,5,6).
Page 198 SCARABEO 500 Engine Refitting the intake manifold - Fit the inlet manifold to the engine. - Insert the 3 fixing screws, one of which with a supporting clamp for the cooling system sleeve, and tighten them to the prescribed torque. Locking torques (N*m) Inlet manifold screws 11 ÷...
Page 199 SCARABEO 500 Engine - Remove the flywheel cover with the cooling system sleeves as described in the «Flywheel cover» chapter. - Remove the magneto flywheel with the start-up control as described in the «Magneto flywheel re- moval» chapter. - Remove the thermal group (cylinder, head, piston) as described in the «Thermal group and Timing system»...
Page 200 SCARABEO 500 Engine - Remove the 14 crankshaft coupling screws. NOTE THE FIXING SCREWS COME IN 3 DIFFERENT LENGTHS. NOTE THEIR CORRECT POSITION. - Detach the crankcase halves keeping the crank- shaft connected to the flywheel-side crankcase half. - Remove the coupling gasket. NOTE THE BUSHING WHICH IS PART OF THE SUP- PORT CAN BE LEFT IN THE FLYWHEEL-SIDE...
Page 201 SCARABEO 500 Engine Countershaft control gear and oil pump remov- - To remove the control gear, undo the 4 fixing screws. Remove the gear only if actually required. CAUTION THESE ARE COUNTERSUNK SCREWS AND THEIR THREADING IS LOCKED WITH LOC- TITE.
Page 202 SCARABEO 500 Engine Replacing the countershaft bearings - Check that the bearings are free from irregular noise or clearance. Otherwise, replace them. Flywheel-side crankcase half - Remove the internal Seeger ring. - Turn the crankcase half over. - Remove the bearing from the flywheel-side crankcase half using the specific tool and a mallet.
Page 203 SCARABEO 500 Engine - First grease the guide seat and then fit a new bearing on the specific tool. - Fit a new bearing on the crankcase half using the specific tool. NOTE IF A BEARING WITH PLASTIC CAGE IS USED, KEEP THE BALLS VISIBLE FROM THE CRANKCASE INTERNAL SIDE.
Page 204 SCARABEO 500 Engine 020359Y 42 x 47 mm adaptor 020439Y 17-mm guide Inspecting the crankshaft components - Check the connecting rod axial clearance. Characteristic Standard clearance: 0.20 ÷ 0.40 mm - Check the connecting rod diametral clearance. Characteristic Standard clearance: 0.046 ÷...
Page 205 SCARABEO 500 Engine - Check that the shim washer is not scored. NOTE IF IT IS REUSED, KEEP ITS ORIGINAL FITTING POSITION. Specific tooling 020074Y Supporting base for checking crankshaft alignment - If the crankshaft-crankcase axial clearance exceeds the standard and the crankshaft does not show any defect, the problem must be due to either excessive wear or wrong machining on the crankcase.
Page 206 SCARABEO 500 Engine - Check that the crankshaft cone, the tab fitting, the oil seal flow, the knurling and the threaded tabs are in good working order. - In case of failure, replace the crankshaft. NOTE CRANKCASE BEARINGS ARE NOT GRINDABLE. The connecting rod cannot be replaced.
Page 207 SCARABEO 500 Engine NOTE THE JET IS FED THROUGH THE MAIN BUSH- INGS. PROPER OPERATION OF THIS COMPO- NENT IMPROVES PISTON CROWN COOLING. CLOGGING HAS EFFECTS THAT ARE DIFFI- CULT TO DETECT (PISTON TEMPERATURE INCREASE). FAILURE OR LEAKAGE CAN CONSIDERABLY CAUSE A DROP IN LUBRI- CATION PRESSURE FOR THE MAIN BUSH- INGS AND CONNECTING ROD.
Page 208 SCARABEO 500 Engine Inspecting the crankshaft plain bearings - In order to obtain proper bushing lubrication, make sure there are both an outstanding lubrica- tion pressure (4.5 bar) and a good oil flow rate. To that end, the bushings must be correctly posi- tioned so as not to obstruct the oil supply channels.
Page 209 SCARABEO 500 Engine MAIN BUSHING CHECK Name Description Dimensions Initials Quantity Type A - Red 1.971 ÷ 1.974 Type B - Blue 1.974 ÷ 1.977 Type C - Yellow 1.977 ÷ 1.980 Type D - Green 1.980 ÷ 1.983 Coupling chart Depending on the type of crankshaft/crankcase coupling, the following types of bushings listed in the table should be used.
Page 210 SCARABEO 500 Engine - Complete FC3 crankcase equipped with bushings to house a category 1 crankshaft and a countershaft with axial distance B. - Complete FC4 crankcase equipped with bushings to house a category 2 crankshaft and a countershaft with axial distance B. NOTE THE CRANKSHAFT CATEGORY IS STAMPED ON THE COUNTERWEIGHT SHOULDER.
Page 211 SCARABEO 500 Engine - Before installing the gear on the crankshaft, thor- oughly clean both coupling surfaces and remove any residues of LOCTITE left in the holes using a brush. Blow with compressed air and degrease the mounting holes on both surfaces to facilitate adherence of the new LOCTITE applied.
Page 212 SCARABEO 500 Engine - Insert the crankshaft on the pin and afterwards into the bushing with great care. - Before inserting it thoroughly, align the oil pump gear with the control gear. - Insert thoroughly and remove the specific tool. NOTE UPON INSERTING THE SHAFT ON THE CRANKCASE HALF, BE CAREFUL NOT TO DAMAGE THE MAIN BEARING WITH THE THREADED TANG OF THE CRANKSHAFT AND WITH THE TIM-...
Page 213 SCARABEO 500 Engine 020376Y Adaptor handle - Insert the gasket on the flywheel-side crankcase half. - Lubricate the main bearing on the transmission- side crankcase half. - Couple both crankcase halves being careful not to damage the bushing on the transmis- sion-side crankcase half with the threaded tang of the crankshaft.
Page 214 SCARABEO 500 Engine Lubrication TECHNICAL SPECIFICATIONS SUMP CAPACITY Specification Desc./Quantity Oil change and filter replacement 1.7 l RECOMMENDED ENGINE OIL Product Description Specifications AGIP CITY HI TEC 4T Engine oil SAE 5W-40, API SL, ACEA A3, JASO MA Synthetic oil OIL PUMP Specification Desc./Quantity...
Page 215 SCARABEO 500 Engine CRANKCASE VENTILATION CHECK Specification Desc./Quantity Device metal reed valve and decantation chamber Conceptual diagrams BASE DIAGRAM Specification Desc./Quantity Camshaft Cylinder-head plane Cylinder-crankcase plane Water pump rotor Minimum oil pressure sensor Oil filter cartridge To the oil sump By-pass valve Oil pump Oil mesh pre-filter...
Page 216 SCARABEO 500 Engine The high pressure section includes all components located on the engine crankcase; while the low pressure section only refers to the thermal group. The trochoidal pump is fitted to the sump and is controlled via a pair of gears. To guarantee the integrity of the pump, a pre-filter is fitted.
Page 217 SCARABEO 500 Engine Diagnosis guide 1 - Minimum oil pressure warning light on with hot engine. CONTINUE - go to point 2 2 - Remove the electric connector of the minimum pressure switch. Check that the warning light turns off. YES - go to point 3 NO go to point 11 3 - Check the actual oil pressure.
Page 218 SCARABEO 500 Engine STANDARD VALUES Specification Desc./Quantity 80°C Temperature 1400 rpm ~ 1.5 bar YES - go to point 7 NO go to point 8 7 - Replace the minimum oil pressure. 8 - If pressure lower than 1.3 ÷ 1.5 bar is measured. CONTINUE - go to point 9 9 - Replace the oil filter and repeat the pressure check with oil at 80°C.
Page 219: Oil Pressure Check
SCARABEO 500 Engine Oil pressure check 1 - In case of oil or oil filter leaks, check the lubrication pressure. CONTINUE go to point 2 2 - Fit the specific tool. Specific tooling AP8140181 Fuel pressure check tool 020434Y Fitting for oil pressure check CONTINUE - go to point 3 3 - Check the system pressure with cold engine and medium - high speed.
Page 220 SCARABEO 500 Engine - Remove the oil pump together with the gearing by undoing the 2 fixing screws through the eyes machined in the gearing. - Remove the gasket. - Remove the two screws and the oil pump cover. - Remove the internal rotor retaining circlip by turn- ing it until the port matches the shaft face.
Page 221 SCARABEO 500 Engine - Remove and wash the rotors thoroughly with pet- rol and compressed air. - Extract the shaft with its gear and check that it is in good working order and without signs of wear. - Reassemble the rotors in the pump body, keep- ing the 2 reference marks visible.
Page 222 SCARABEO 500 Engine - Check the rotor axial clearance using a trued bar as reference plane, as shown in the figure. Characteristic Limit value allowed: 0.1 mm Refitting - Make sure the gasket is in the correct position. NOTE THE TOOTH OF THE GASKET MUST BE IN ITS SEAT.
Page 223 SCARABEO 500 Engine Failure to observe the tightening torque may alter the coupling clearance between the rotors and the pump body. Locking torques (N*m) Screws fixing oil pump to crankcase 5 ÷ 6 - Fit the countershaft with the gearing to the fly- wheel-side crankcase half.
Page 224 SCARABEO 500 Engine - Remove the six screws and the pump cover. - With an 8-mm wrench, unscrew the water pump rotor. - Use two flat blade screwdrivers, and place them as shown in the figure so as to lever on the marked crankcase edge and disassemble the overall seal- ing, pressure-fitted on the rotor shaft.
Page 225 SCARABEO 500 Engine - Clean thoroughly all the parts before removing them. - Place the extractor complete with pin on the static part of the ceramic seal. - Without modifying the extractor position, make three holes on the static part of the seal using the pin supplied and a hammer.
Page 226 SCARABEO 500 Engine - Hold the screw in one position and operate the nut until the static part of the sealing is completely removed. - Remove the extractor with the static part of the overall sealing. montaggio OVERALL SEALING FITTING CAUTION CLEAN ALL THE COMPONENTS CAREFULLY.
Page 227 SCARABEO 500 Engine - Place the calibrated punch (with preloading val- ues). - Apply the nut to the tie rod. - Keep the tie rod firm and screw the nut up to the end of stroke. - The tool drives the fixed seat on the crankcase and the movable seat on the shaft, producing the correct ceramic seal preloading.
Page 228 INDEX OF TOPICS INJEC NJECTION...
Page 229 SCARABEO 500 Injection KEY: 1. Instrument panel 2. Battery 3. Coolant temperature sensor 4. Fuel injector 5. Throttle body and injection ECU (MIU) 6. Diagnostics connector 7. Engine revolution sensor 8. Lambda probe 9. HV coil 10. Fuel pump 11. Fan 12.
Page 230 SCARABEO 500 Injection - Coolant temperature - Intake air temperature - Lambda probe value The system implements an idle supply correction with cold engine through a Stepper motor on a by- pass circuit of the throttle valve. The electronic control unit manages the Stepper motor and the injector opening time, thereby ensuring idle steadiness and proper carburetion.
Page 231 SCARABEO 500 Injection The control unit is fitted with a self-diagnosis sys- tem connected to a warning light on the instrument panel. Failures are detected and restored by the diag- nostic tester. The MIU injection-ignition system carries out checks on the rpm indicator and the radiator cooling elec- tric fan.
Page 232 SCARABEO 500 Injection 10. Do not invert the polarity when fitting the battery. 11. In order to prevent damages, disconnect and reconnect the MIU system connectors only if actually required. Before restoring the connections, check that they are perfectly dry. 12.
Page 233 SCARABEO 500 Injection C see whether the malfunction can be fixed by slightly shaking the connector. 3 Check the entire system carefully before replacing the MIU control unit. If the fault is still present after the MIU control unit is replaced, install the original control unit again and check whether the fault occurs again.
Page 234 SCARABEO 500 Injection Specification Desc./Quantity Start-up enabling Fall sensor Ground connection EMS circuit diagram SYSTEM DIAGRAM Specification Desc./Quantity Injection electronic control unit Water Temperature Sensor Electric fan remote control HV coil Fuel injector Fuel pump Lambda Probe Injection load remote control stand switch Engine revolution sensor Battery...
Page 235: Troubleshooting Procedure
SCARABEO 500 Injection Specification Desc./Quantity Stop switch Engine stop switch Starter button Fall sensor Instrument panel Electric fan Connector for diagnosis Troubleshooting procedure Engine does not start ENGINE DOES NOT START EVEN IF PULLED Possible Cause Operation Faults detected by self-diagnosis Pump relay HV coil Injector...
Page 236 SCARABEO 500 Injection Possible Cause Operation Ignition advance Fuel supply Fuel pressure (low) Injector flow (low) Injector seal (poor) Correctness of the parameters Coolant temperature Intake air temperature Stepper throttle valve posi- tion (steps and actual opening) Cleaning the auxiliary air pipe and air filter effi- ciency throttle valve Engine stops at idle ENGINE DOES NOT HOLD IDLING/ IDLING IS UNSTABLE/ IDLING TOO LOW...
Page 237 SCARABEO 500 Injection Possible Cause Operation Coolant temperature sensor Intake air temperature sensor Intake system seal (seepage) Intake manifold - head Throttle body - manifold Intake manifold Filter housing Fuel supply (low pressure) Fuel pump Pressure regulator Fuel filter Injector flow Exhaust backfires in deceleration EXHAUST BACKFIRING WHEN DECELERATING Possible Cause...
Page 238 SCARABEO 500 Injection Possible Cause Operation Ignition advance TPS reset successful TPS reset successful Faults detected by self-diagnosis Pump relay HV coil Injector Revolution timing sensor Air temperature Coolant temperature Lambda Probe Poor performance at full throttle POOR ENGINE PERFORMANCE AT FULL POWER/ IRREGULAR ENGINE PROGRESS ON ACCELERATION Possible Cause Operation...
Page 239 SCARABEO 500 Injection Possible Cause Operation Coolant temperature signal Intake air temperature signal Ignition advance Intake system seal Intake manifold Filter housing TPS reset successful TPS reset successful Fuel supply Fuel pressure Fuel filter Injector flow Fuel quality Selecting the thickness for the cylinder base gas- Selecting the thickness for the cylinder base gas- Fuel supply system The fuel supply circuit includes the electric pump, the filter, the pressure regulator, the electro-injector...
Page 240 SCARABEO 500 Injection Removing the butterfly valve • Remove the fuel piping fixing screw in- dicated in the figure. • Remove the fast-release fitting from the injector support. • Remove the injector connector. • Remove the three screws fixing the manifold to the cylinder head and the clamp fixing the throttle body to the manifold.
Page 241 SCARABEO 500 Injection • Remove the MIU control unit connector • Remove throttle control retainer. INJEC - 241...
Page 242 SCARABEO 500 Injection Pump supply circuit INJECTION LOAD Specification Desc./Quantity Injection electronic control unit Electric fan remote control HV coil Fuel injector Fuel pump Lambda Probe Injection load remote control Battery Fuse 30 A Fuse 10 A Fuse 15 A Key switch contacts Key remote control switch relay When switched to "ON", the fuel pump starts to rotate for 2 seconds and then stops.
Page 243 SCARABEO 500 Injection Check the efficiency of the 15A fuse «A». Check the efficiency of the injection load remote control: Check the resistance of the drive coil be- tween pins 86 and 85: 40 ÷ 80 Ohm. Apply a voltage of 12V to pins 86 and 85; make sure that there is continuity between pins 30 and 87 of the remote control.
Page 244 SCARABEO 500 Injection Check there is voltage between the Green-Red cable of the remote control base and the ground lead. Upon switching to "ON", check that there is battery voltage for about two seconds between the Red- Brown cable of the pump connector and ground connection, with the pump connector disconnec- ted.
Page 245 SCARABEO 500 Injection Checking under regular functioning by placing the specific tool between the pump and the injector. With >12V battery voltage, check that the fuel pressure is 3 BAR and that the input current is ~2.8 With the >12V battery voltage, check the pump flow rate by disconnecting the pipe fitted with the pres- sure gauge of the appropriate tool from the injector.
Page 246 SCARABEO 500 Injection Remove the clip fixing the piping to the filter shown in the photograph Separate the lower part of the pump support as shown in the photograph. Remove the filter from the pump support INJEC - 246...
Page 247 SCARABEO 500 Injection Inspecting the injector circuit INJECTION LOAD Specification Desc./Quantity Injection electronic control unit Electric fan remote control HV coil Fuel injector Fuel pump Lambda Probe Injection load remote control Battery Fuse 30 A Fuse 10 A Fuse 15 A Key switch contacts Key remote control switch relay When switched to "ON", the fuel pump starts to rotate for 2 seconds and then stops.
Page 248 SCARABEO 500 Injection Check the efficiency of the 15A fuse «A». Check the efficiency of the injection load remote control: Check the resistance of the drive coil be- tween pins 86 and 85: 40 ÷ 80 Ohm. Apply a voltage of 12V to pins 86 and 85; make sure that there is continuity between pins 30 and 87 of the remote control.
Page 249 SCARABEO 500 Injection Check there is voltage between the Green-Red cable of the remote control base and the ground lead. With both the control unit and the injector discon- nected, check the continuity of the Grey-Red cable between pin 14 of the interface wiring and the in- jector connector.
Page 250 SCARABEO 500 Injection Fit the appropriate tool to check fuel pressure and position the manifold over a graded container, with a minimum capacity of 100 cm³. Connect the in- jector with the cable that is part of the components supplied for the injection tester. Connect the cable terminals to an auxiliary battery.
Page 251 SCARABEO 500 Injection Tachometer With the wiring disconnected from the control unit and connected to the system, check that the sen- sor resistance between pins 13 - 15 is between 100 and 150 Ohm at an engine temperature of about 20° Disconnect the fuel pump connector.
Page 252 SCARABEO 500 Injection With the interface wiring disconnected from the control unit, check continuity between pin 13 and the Red cable of the rpm sensor connector and between pin 15 and the White cable of the rpm sensor connector. With the interface wiring disconnected from the control unit and the rpm sensor connector also disconnected, check that the Red and White ca- bles (pin 13 - 15) are insulated from each other and...
Page 253 SCARABEO 500 Injection Specification Desc./Quantity Electric fan remote control HV coil Fuel injector Fuel pump Lambda Probe Injection load remote control Battery Fuse 30 A Fuse 10 A Fuse 15 A Key switch contacts Key remote control switch relay The combined ignition/injection system is a high-efficiency induction system. The control unit manages two significant parameters: - Ignition advance This is optimised at once according to the engine revs, engine load, temperature and ambient pressure.
Page 254 SCARABEO 500 Injection Check the power supply line of the injection load remote control drive coil: upon switching to "ON", make sure there is battery voltage for 2 seconds between the Red-Yellow cable and the Green-Red cable of the remote control base. If there is none, check the continuity of the Green-Red cable be- tween the fuse box and the remote control base and check the continuity of the Red-Yellow cable...
Page 255 SCARABEO 500 Injection Check the resistance of the coil primary between pin 22 of the interface wiring and the Red-Brown cable of the injection load remote control base, with both the control unit and the remote control disconnected. Electric characteristic Resistance of the primary ~ 1 Ohm Inspecting the spark plug shielded cap...
Page 256 SCARABEO 500 Injection The ignition advance value can be measured at any time with the diagnostic tester. It is possible to check whether the ignition advance determined by the injection system does in fact correspond with the value actually activated on the engine, by means of the stroboscopic light. Proceed as follows: - Remove the external transmission cover as des- cried in the «Automatic transmission»...
Page 257: Coolant Temperature Sensor
SCARABEO 500 Injection - Refit the inspection cap on the flywheel side. - Connect the diagnostic tester. - Start the engine. - Select the «parameter» function from the menu. - Select the stroboscopic light control in the tradi- tional four-stroke engine position (1 spark, 2 revs). - Check that the real values of revs and ignition advance match those measured using the diag- nostic tester.
Page 258 SCARABEO 500 Injection With the control unit-side connector disconnected and the coolant temperature sensor connector connected, check the resistance values between pin 9 and the ground connection match the engine temperature. 20° = 2500 ± 100 80° = 308 ± 6 With the control unit-side connector disconnected and the coolant temperature sensor connector al- so disconnected, check the insulation between the...
Page 259 SCARABEO 500 Injection After the pre-calibration the throttle body has an open valve with a variable angle depending on the tolerances of the machining of the pipe and the valve itself. The valve position sensor can also have various fitting positions. For these reasons the mVs of the sensor with the valve at idle can vary from one throttle body to another.
Page 260 SCARABEO 500 Injection Lambda probe INJECTION LOAD Specification Desc./Quantity Injection electronic control unit Electric fan remote control HV coil Fuel injector Fuel pump Lambda Probe Injection load remote control Battery Fuse 30 A Fuse 10 A Fuse 15 A Key switch contacts Key remote control switch relay The lambda probe or oxygen sensor is a sensor which provides information about the oxygen content in the exhaust fumes.
Page 261 SCARABEO 500 Injection Check the efficiency of the 15A fuse «A». Check the efficiency of the injection load remote control: Check the resistance of the drive coil be- tween pins 86 and 85: 40 ÷ 80 Ohm. Apply a voltage of 12V to pins 86 and 85; make sure that there is continuity between pins 30 and 87 of the remote control.
Page 262 SCARABEO 500 Injection Check there is voltage between the Green-Red cable of the remote control base and the ground lead. Install the electronic control unit interface wiring. Start the engine and warm it up until the electric fan switches on. Use an analogue multimeter with a direct voltage scale measuring down to 2V.
Page 263 INDEX OF TOPICS SUSP USPENSIONS...
Page 264 SCARABEO 500 Suspensions Front Front fork diagram Key: 1. Fork base 2. Fork clamp screws 3. O-Ring 4. Circlip 5. Sealing cap 6. Spring 7. Pumping member 8. Counter spring 9. End stop buffer 10. Left stem 11. Dust guard gasket 12.
Page 265: Removing The Front Wheel
SCARABEO 500 Suspensions 18. Lower screw 19. Right stem 20. Right wheel holder 21. Locking screw 22. Sliding bushing Removing the front wheel Key: 1. Wheel bolt 2. Odometer sensor 3. Right oil seal 4. Right bearing 5. Wheel 6. Internal spacer 7.
Page 266: Front Fork
SCARABEO 500 Suspensions • Working from both sides, undo and remove the two calliper fixing screws. • Remove both callipers from the front brake discs . • Position the vehicle on the front service stand (OPT). • Loosen the wheel bolt fixing screw on the right fork stem.
Page 267 SCARABEO 500 Suspensions Removal FORK REMOVAL • Drain off the oil. • Place the stem in a vice fitted with (alu- minium) protection jaws. • Undo and remove the lower screw «1» and collect the washer. • Slide off the stem from the sleeve and collect the bushing.
Page 268 SCARABEO 500 Suspensions • Slide off the snap ring «5» from the sleeve. • Slide off the oil seal «6» from the sleeve. • Slide off the washer 7» from the sleeve. • Slide off the bushing 8» from the sleeve.
Page 269 SCARABEO 500 Suspensions • Place the sleeve in a vice. CAUTION THE WHEEL HOLDER STEM SLEEVE UNIT CONTAINS OIL. DO NOT TURN IT OVER OR TILT IT TOO MUCH WHEN REMOVING IT. • Lower the cap «1» until the Seeger ring «2»...
Page 270 SCARABEO 500 Suspensions • Drain off the oil into the collecting con- tainer by pumping it out with the stem. • Hold the front part of the vehicle with a belt and a hoist. • Remove the front wheel. • Undo and remove screw for the front brake hose guide.
Page 271 SCARABEO 500 Suspensions • Unscrew and remove the screw fixing the speed sensor and collect the nut. • Loosen the two screws fixing the fork stem. • Remove the upper retainer «2». • Remove the wheel holder stem «3» by pulling it from the below.
Page 272 SCARABEO 500 Suspensions Bending limit: 0.2 mm Sleeve • Check that there are no damages and/ or cracks; otherwise, replace it. • If there are signs of excessive wear or damage, replace the affected compo- nent. Replace the following components with new ones: - O-ring gasket on the cap «1»;...
Page 273 SCARABEO 500 Suspensions • Insert the oil seal. • Fit the snap ring. • Fit the dust guard. • Insert the pumping member and the spring in the stem. SUSP - 273...
Page 274 SCARABEO 500 Suspensions • Insert the stem together with the bush- ing «2» in the sleeve. • Tighten the lower screw «3» together with its washer. • Fill with oil. OIL FILLING • Place the wheel holder stem sleeve unit in a vice fitted with (aluminium) protection jaws.
Page 275 SCARABEO 500 Suspensions • Fit the spring. • Fit the cap «1» together with the O- ring. • Lower the cap «1» until the Seeger ring «2» can be inserted. • Fit the Seeger ring «2». Rear SUSP - 275...
Page 276: Removing The Rear Wheel
SCARABEO 500 Suspensions Removing the rear wheel Key: 1. Complete wheel 2. Split pin 3. Cap 4. Nut 5. External spacer 6. Screw 7. Washer 8. Washer 9. Internal spacer 10. Wheel hub 11. Brake disc SUSP - 276...
Page 277 SCARABEO 500 Suspensions • Working on the right side of the vehicle, undo and remove the two side screws fixing the rear mudguard; collect the two shim washers. • Loosen the clamp of the exhaust mani- fold. • Undo and remove the screw fixing the exhaust end sealing clamp.
Page 278 SCARABEO 500 Suspensions • Remove the safety split pin. • Remove the cap. • With the help of a second operator, op- erate the rear brake; unscrew and re- move the rear nut fixing the muffler supporting bracket. SUSP - 278...
Page 279 SCARABEO 500 Suspensions • Unscrew and remove the two front nuts fixing the muffler supporting plate. • Remove the muffler supporting plate. SUSP - 279...
Page 280 SCARABEO 500 Suspensions • Remove the spacer. • Undo and remove the five screws fixing the wheel. • Remove the wheel. NOTE PLACE AN ADEQUATE SUPPORT AT THE LOWER PART OF THE MOTOR VEHICLE. SUSP - 280...
Page 281 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...
Page 282 SCARABEO 500 Braking system Braking system diagram NOTE THIS VEHICLE IS FITTED WITH A BRAKING SYSTEM COMPRISING: • TWO BRAKE DISCS ON THE FRONT WHEEL; • ONE BRAKE DISC ON THE REAR WHEEL; • A RETARDING VALVE LOCATED UNDER THE HEADLAMP. Operating the right (front) brake lever exerts pressure on the front right brake calliper.
Page 283 SCARABEO 500 Braking system 3. Pads - torques 4. Pins + spring set 5. Bleed pipe 6. Bleed pipe cap 7. M8x35 TCEI screw 8. Front brake pipe 9. Front calliper distribution pipe 10. Retarding valve 11. M6X20 TE flanged screw 12.
Page 284: Front Brake Pads
SCARABEO 500 Braking system • Undo the two screws indicated and re- move the brake calliper. NOTE SHOULD IT BE NECESSARY TO REPLACE THE CALLIPER, FIRST LOOSEN THE FITTING CONNECTING THE PIPE TO THE BRAKE CAL- LIPER. Refitting • To fit, follow the removal steps but in reverse order, and tighten the locking screws to the prescribed torque using the recommended product.
Page 285 SCARABEO 500 Braking system • Remove the brake calliper. • Undo the two screws indicated. • Push the floating pad of the calliper. • Remove the brake pads. CAUTION AFTER REMOVING THE PADS, DO NOT OP- ERATE THE BRAKE CONTROL LEVER; OTH- ERWISE, THE CALLIPER PLUNGER COULD GO OUT OF ITS SEAT RESULTING IN BRAKE FLUID LEAKAGE.
Page 286: Rear Brake Pads
SCARABEO 500 Braking system • In case of uneven wear, replace the pads when there is a thickness differ- ence of 0.5 mm in the friction material. CAUTION ALWAYS REPLACE BOTH PADS AND MAKE SURE THEY ARE CORRECTLY POSITIONED INSIDE THE CALLIPER. Refitting •...
Page 287 SCARABEO 500 Braking system • Slide off the pin. • Remove the spring. • Slide off the brake pads. CAUTION AFTER REMOVING THE PADS, DO NOT OP- ERATE THE BRAKE CONTROL LEVER; OTH- ERWISE, THE CALLIPER PLUNGER COULD GO OUT OF ITS SEAT RESULTING IN BRAKE FLUID LEAKAGE.
Page 288 SCARABEO 500 Braking system • In case of uneven wear, replace the pads when there is a thickness differ- ence of 0.5 mm in the friction material. CAUTION ALWAYS REPLACE BOTH PADS AND MAKE SURE THEY ARE CORRECTLY POSITIONED INSIDE THE CALLIPER. Refitting •...
Page 289 SCARABEO 500 Braking system • Insert the cotter pin. • Fit the rear wheel. Fill - Bleeding the braking system Rear - combined Distribution valve • Remove the front central cover. • Remove the rubber protection cover «2» from the bleed valve «3». •...
Page 290 SCARABEO 500 Braking system • Top-up the reservoir until the correct brake fluid level is obtained. • Refit the rubber protection cover. Front brake • Remove the rubber protection cover from the bleed valve «4». • Insert a transparent plastic pipe on the bleed valve «4»...
Page 291 SCARABEO 500 Braking system • Loosen the bleed valve 1/4 of a turn so that the brake fluid flows into the con- tainer. This will release tension on the brake lever and will make it go to the end of stroke. •...
Page 292 SCARABEO 500 Braking system Rear brake pump - combined Removal • Remove the legshield. • Undo and remove the three screws fix- ing the antitheft control unit. • Detach the antitheft control unit but keep it connected to the wiring. •...
Page 293 INDEX OF TOPICS COOL SYS OOLING SYSTEM...
Page 294: Circuit Diagram
SCARABEO 500 Cooling system Circuit diagram KEY: 1. Radiator 2. Expansion tank 3. Expansion tank support 4. Head-radiator fitting pipe 5. Pump-radiator fitting pipe 6. Electric fan support 7. Electric fan 8. Spacer bushing 9. Upper fixing rubber ring 10. Lower fixing rubber ring 11.
Page 295: Coolant Replacement
SCARABEO 500 Cooling system 17. M5X12 TE flanged screw 18. M5 Clip 19. M6 Clip 20. Flanged self-locking M6 nut 21. Clamp, D.16 24X8 22. Clamp, D.16 24X8 23. Pipe clamp 24. Expansion tank cap 25. Aluminium washer, 14X22X1 26. Filler rubber ring 27.
Page 296 SCARABEO 500 Cooling system System top-up instructions • Fill the system up to a level ranging be- tween the MIX and MAX levels indica- ted in the expansion tank filler. • Do not close the expansion tank with the cap. Recommended products AGIP PERMANENT SPEZIAL Coolant Biodegradable coolant, ready for use, with "long...
Page 297 SCARABEO 500 Cooling system Water pump - overhaul In case of noise or fluid leaks from the water pump drainage hole, inspect the pump as described in the «Engine/Water pump» Chapter. Proceed to carry out a few preliminary operations as described below: •...
Page 298 SCARABEO 500 Cooling system • Refit the water pump cover and tighten the six fixing screws to the prescribed torque. Locking torques (N*m) Water pump cover screws 3 ÷ 4 Water pump ceramic seal Our fluid-cooled engines are fitted with water pumps made with this type of ceramic seal. This element ensures coolant tightness at the pump shaft.
Page 299 SCARABEO 500 Cooling system 2 - Check the head gasket seal (see the «Thermal group and Timing system» chapter) COOL SYS - 299...
Page 300 INDEX OF TOPICS CHAS HASSIS...
Page 301 SCARABEO 500 Chassis Seat It is necessary to lift the saddle before removing it. There are two ways to do so: • use the supplied remote control, press the key «1» and the saddle will open automatically. • Insert the key in the key lock and press down.
Page 302: Instrument Panel
SCARABEO 500 Chassis SADDLE OPENING SYSTEM REMOVAL • Remove the central inspection cover (SEE TAIL SECTION). • Remove the control cable. • Release the control cable and the sad- dle unlocking cable. • Remove the connector. • Undo and remove the two fixing screws.
Page 303 SCARABEO 500 Chassis • Detach the handlebar protection. • Undo and remove both upper screws fixing the instrument panel. • Remove the front handlebar cover. • Disconnect the instrument panel con- nector. CHAS - 303...
Page 304 SCARABEO 500 Chassis • Undo and remove the two lower screws fixing the rear handlebar cover. • Remove the rear handlebar cover to- gether with the instrument panel. Headlight assy. • Undo and remove the screw fixing the headlamp front cowl. •...
Page 305 SCARABEO 500 Chassis • Undo and remove both screws fixing the headlamp to the chassis. • Move the headlamp and disconnect the connector. • Remove the headlamp; be careful not to damage it. Legshield • Rest the vehicle on its centre stand. •...
Page 306 SCARABEO 500 Chassis Remove the legshield to access: - the expansion tank; - the turn indicator bulbs; - the voltage regulator; - the horn; - the relay; - the fall sensor; - the antitheft control unit. Knee-guard • Remove the legshield. •...
Page 307 SCARABEO 500 Chassis Footrest • Remove the tail section. • Remove the central tunnel. • Undo and remove the two lower screws. • Remove the plastic footrest. • Undo and remove the two upper screws. • Remove the footrest. CHAS - 307...
Page 308 SCARABEO 500 Chassis Air filter • Working on the left side of the vehicle, undo and remove the two side screws fixing the rear mudguard and collect the two washers. NOTE UPON REFITTING, PAY ATTENTION TO THE LENGTH OF THE FIXING SCREWS, THE REAR SCREW IS SHORTER.
Page 309 SCARABEO 500 Chassis • Loosen the intake manifold clamp. • Remove the clamp indicated. • Slide off the bleed pipe. • Remove the filter housing. Tail guard • Rest the vehicle on its centre stand. • Working on both sides, open the pas- senger footrest.
Page 310 SCARABEO 500 Chassis • Lift the saddle. • Undo and remove the two upper screws fixing the central inspection cover. • Undo and remove the lower screw fix- ing the central inspection cover. • Lower the saddle. • Remove the central inspection cover. •...
Page 311 SCARABEO 500 Chassis • Working on both sides, undo and re- move the two side lower fixing screws. • Undo and remove the four screws fix- ing the passenger grab handle. • Remove the cover. • Undo and remove the three screws fix- ing the passenger grab handle.
Page 312 SCARABEO 500 Chassis • Remove the rear light upper lock. • Undo and remove the two rear screws fixing the tail section. • Disconnect the three connectors. • Remove the tail section together with the rear light. • Once the tail section is removed, the fairings can also be removed by loos- ening the three screws indicated on both sides.
Page 313 SCARABEO 500 Chassis Helmet bay • Lift the saddle. • Undo and remove the two screws fixing the battery cover. • Remove the battery protection cover. • Remove the tail section. • Remove the saddle. • Disconnect the electrical connector. •...
Page 314 SCARABEO 500 Chassis • Slide off the cables from the helmet compartment. • Undo and remove the fixing screw of the helmet compartment light switch. • Disconnect the two connectors of the helmet compartment light switch. • Remove the helmet compartment light bulb. CHAS - 314...
Page 315 SCARABEO 500 Chassis • Undo and remove the two front screws. • Working on both sides, undo and re- move the side screws. • Undo and remove the two rear screws. • Undo and remove the screws fixing the helmet compartment - license plate. CHAS - 315...
Page 316: Fuel Tank
SCARABEO 500 Chassis • Remove the helmet compartment. Fuel tank Fuel supply diagram Key: 1. Fuel tank 2. Fuel tank cap 3. Fuel level probe 4. Fuel pump 5. Fuel pump fixing ring nut gasket 6. Fuel pump fixing ring nut 7.
Page 317 SCARABEO 500 Chassis 10. Rubber ring 11. M6 Clip 12. M6X20 TE flanged screw 13. Fuel pipe, D5.5x10 14. 6.6x18x1.6 Washer Tank removal • Remove the front central cover. • Remove the tail section. • Remove the footrest. • Remove the stem covers. •...
Page 318 SCARABEO 500 Chassis • Move the spoiler towards the mud- guard so as access the tank under- neath and front parts. • Working on both sides, undo and re- move the screw of the rear lower sup- porting cross-member. • Remove the cross-member.
Page 319 SCARABEO 500 Chassis • Undo and remove the tank rear fixing screw. • Detach the fuel tank from the chassis and remove it. Expansion tank • Drain off the cooling system. • Remove the legshield. • Detach the expansion tank from the breather pipe «3».
Page 320 SCARABEO 500 Chassis • Remove the screw «1» placed under each footrest. • Remove the shield back plate. • Remove the two screws «2». CHAS - 320...
Page 321 INDEX OF TOPICS PRE DE DELIVERY...
Page 322 SCARABEO 500 Pre-delivery Before handing over the vehicle, carry out the checks listed below. WARNING BE EXTREMELY CAUTIOUS WHEN HANDLING FUEL. Aesthetic inspection - Paintwork - Fitting of plastic parts - Scratches - Dirt Tightening torques inspection - Safety Locks: front and rear suspension unit front and rear brake calliper retainer unit front and rear wheel unit...
Page 323: Road Test
SCARABEO 500 Pre-delivery - Through the diagnosis instrument, check that the last mapping version is present in the control unit/s and reprogram the control unit/s, if required: consult the technical service website to know if there are available upgrades and for details on the operations. CAUTION TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE.
Page 324 SCARABEO 500 Pre-delivery - Front and rear brake efficiency - Front and rear suspension efficiency - Abnormal noise Static test Static check after test drive: - Restarting when warmed up - Starter operation (if present) - Idle speed (turning the handlebar)) - Uniform turning of the steering - Possible leaks - Radiator electric fan operation (if present)

APRILIA SCARABEO 500 2008 Service Station Manual

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