APRILIA Scarabeo 50 2T2006 Workshop Manual
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APRILIA Scarabeo 50 2T2006 Workshop Manual

APRILIA Scarabeo 50 2T2006 Workshop Manual

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Scarabeo 50 2T (PA C421M)
1315 6
01/2006-00
workshopmanual

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Summary of Contents for APRILIA Scarabeo 50 2T2006

  • Page 1 Scarabeo 50 2T (PA C421M) 1315 6 01/2006-00 workshopmanual...
  • Page 2 UPDATE Scarabeo 50 2T (PA C421M) UPDATE 2 - 1...

  • Page 3: Table Of Contents

    UPDATE C421M Scarabeo 50 2T (PA SUMMARY 2.1. INTRODUCTION ............................. 3 2.1.1. FOREWORD............................3 2.1.2. REFERENCE MANUALS........................4 2.1.3. VEHICLE IDENTIFICATION ........................5 2.1.4. SPECIFICATIONS ..........................6 2.1.5. RUNNING-IN............................8 2.1.6. LUBRICANT TABLE..........................9 2.2. SCHEDULED MAINTENANCE........................10 2.2.1. SCHEDULED MAINTENANCE CHART....................10 2.2.2.

  • Page 4: Introduction

    manual.

  • Page 5: Reference Manuals

    (description) 8202447 8202453 8202454 WORKSHOP MANUAL SCARABEO 50 4S (PA C373M) – 100 4S (PA M226M) – 50 2S (APRILIA ENGINE) MY03 aprilia part# (description) 8140601 8140602 CD FOR THE NETWORK - CHASSIS SCARABEO 50 4S (PA C373M) – 100 4S (PA M226M) – 50 2S (APRILIA ENGINE) MY03...

  • Page 6: Vehicle Identification

    UPDATE Scarabeo 50 2T (PA C421M) 2.1.3. VEHICLE IDENTIFICATION POSITION OF THE SERIAL NUMBERS These numbers are necessary for the registration of the vehicle. NOTE Do not alter the identification numbers if you do not want to incur severe penal and administrative sanctions; in particular, altering the frame number voids the warranty.

  • Page 7: Specifications

    UPDATE C421M Scarabeo 50 2T (PA 2.1.4. SPECIFICATIONS DIMENSIONS Max. length 1875 mm (73.82 in.) Max. width (at brake levers) 710 mm (27.95 in.) Max. height (at rear-view mirrors) 1270 mm (50 in.) Seat height 700 mm (27.56) Wheelbase 1245 mm (49.01 in.) Minimum ground clearance 145 mm (5.71 in.) Loadless weight (in running order)
  • Page 8 UPDATE Scarabeo 50 2T (PA C421M) TYRES Front 2.50 x 16” – 42J SAVA MC 26 CAPRI 46M REINF Standard inflating pressure (front) 190 kPa (1.9 bar) Inflation pressure with passenger (in the countries where 190 kPa (1.9 bar) this is allowed) Rear 2.75 x 16”...

  • Page 9: Running-In

    UPDATE C421M Scarabeo 50 2T (PA 2.1.5. RUNNING-IN After the first 500 km (312 mi), 1000 km (625 mi), carry out the checks indicated in the column “After running-in” of SCHEDULED MAINTENANCE INTERVALS CHART, see (SCHEDULED MAINTENANCE CHART), in order to avoid hurting yourself or other people and/or damaging the vehicle.

  • Page 10: Lubricant Table

    UPDATE Scarabeo 50 2T (PA C421M) 2.1.6. LUBRICANT TABLE LUBRICANT PRODUCT Transmission fluid RECOMMENDED: F.C., SAE 75W – 90 or GEAR SYNTH, SAE 75W - 90. As an alternative to recommended fluids, top brand oils meeting or exceeding A.P.I. GL-4 specifications can be used. Mixer oil RECOMMENDED: GREEN HIT 2 or...

  • Page 11: Scheduled Maintenance

    UPDATE C421M Scarabeo 50 2T (PA 2.2. SCHEDULED MAINTENANCE 2.2.1. SCHEDULED MAINTENANCE CHART After running-in Every 4000 km Every 8000 km Component [500 km (2500 mi) (5000 mi) or 24 (312 mi)] or 12 months months Battery – Clamp tightening - Electrolyte level Spark plug Carburettor - idling Air filter...

  • Page 12: Mixer Oil

    In the event you run out of mixer oil or the mixer oil hose is removed, contact an aprilia Authorised dealer that will bleed the system. This operation is necessary because engine might be damaged if running with air in the mixer oil system.

  • Page 13: Adjusting The Rear Brake

    UPDATE C421M Scarabeo 50 2T (PA 2.2.3. ADJUSTING THE REAR BRAKE • Measure lever stroke distance before braking action is started. • The lever idle stroke measured at lever end shall be about 10 mm (0.39 in). Adjusting clearance: • Force spring (1) to gain access to seat (2) of threaded linkage.

  • Page 14: Engine

    UPDATE Scarabeo 50 2T (PA C421M) 2.3. ENGINE 2.3.1. REMOVING THE 50 2S ENGINE • To remove the crankcase, first remove the fuel tank and mixer oil tank, see (REMOVING THE FUEL AND MIXER OIL TANKS), the battery, see (REMOVING THE BATTERY), the lower shield, see (REMOVING LOWER SHIELD)
  • Page 15 UPDATE C421M Scarabeo 50 2T (PA • Disconnect the spark plug cap. • Remove the rubber protection. • Disconnect the automatic choke connector. • Remove clamp disconnect generator connector. • Prepare a suitable support under transmission. 2 - 14...
  • Page 16 UPDATE Scarabeo 50 2T (PA C421M) • Remove rear wheel nut cap. • Loosen and remove the rear wheel nut. • Remove the rear wheel from the side. • Unscrew and remove the screw. 2 - 15...
  • Page 17 UPDATE C421M Scarabeo 50 2T (PA • Loosen and remove the screw, moving aside the ground cable. • Remove the starter motor with O-ring and move it backward. • Loosen the screw and disconnect the connector. • Remove the starter motor. •...
  • Page 18 UPDATE Scarabeo 50 2T (PA C421M) • Fasten the shock absorber to the frame. • Remove the tie and disconnect the vacuum hose. • Loosen and remove the screw and remove the throttle cable. • Using a screwdriver, remove the oil pump plug. 2 - 17...
  • Page 19 UPDATE C421M Scarabeo 50 2T (PA • Loosen oil pump adjuster nut. • Loosen the key and release the peg from pulley. • Loosen the adjuster and remove the oil pump adjuster cable. NOTE Perform the following operations together with another operator.
  • Page 20 UPDATE Scarabeo 50 2T (PA C421M) • Slide out pin on the right side tapping on the other side with a rubber mallet. • Remove the frame from the front. 2 - 19...

  • Page 21: Installing The 50 2S Engine

    UPDATE C421M Scarabeo 50 2T (PA 2.3.2. INSTALLING THE 50 2S ENGINE • With another operator, move the frame close to the engine and secure its rear end to an A-frame using a sling. • Move the frame in small motions until the holes match perfectly.
  • Page 22 UPDATE Scarabeo 50 2T (PA C421M) • Tighten the nut. • Fit oil pump plug. • Fit throttle cable and tighten the screw. 2 - 21...
  • Page 23 UPDATE C421M Scarabeo 50 2T (PA • Connect the vacuum hose and fasten with the tie. • Remove the shock absorber from the frame. • Fit the screw and tighten the nut. • Connect connector and tighten the screw. • Start screw on ground cable and on starter motor front hole.
  • Page 24 UPDATE Scarabeo 50 2T (PA C421M) • Tighten the rear screw. • Tighten both screws on starter motor. • Fit the rear wheel. • Tighten the rear wheel nut. • Fit rear wheel nut cap. 2 - 23...
  • Page 25 UPDATE C421M Scarabeo 50 2T (PA • Connect the generator connector. • Connect automatic choke connector and correctly position the rubber protection. • Fit the spark plug cap. • Fit rear brake cable together with spring and washer. • Tighten adjuster nut. •...
  • Page 26 UPDATE Scarabeo 50 2T (PA C421M) • Tighten front cable guide screw. • Set cable into cable guide and tighten the screw. • Install the exhaust, the mixer oil and fuel tank, the battery and the lower shield. • When engine is reinstalled, proceed as follows. NOTE Ensure engine screws/nuts are correctly tightened to the specified torque.

  • Page 27: Fuel Feed System

    UPDATE C421M Scarabeo 50 2T (PA 2.4. FUEL FEED SYSTEM 2.4.1. FUEL SUPPLY SYSTEM DIAGRAM Key: Fuel level sensor Fuel tank plug Fuel collection rubber element Fuel tank Oil tank plug Oil reserve indicator Oil reservoir Screw M5x10 Washer 10. Mixer oil filter 11.

  • Page 28: Removing The Fuel And Mixer Oil Tanks

    UPDATE Scarabeo 50 2T (PA C421M) 2.4.2. REMOVING THE FUEL AND MIXER OIL TANKS • Remove the passenger grab handle, see (REMOVING THE PASSENGER GRAB HANDLE). • Remove the seat, see (REMOVING THE SEAT). • Release and remove the six screws. •...
  • Page 29 UPDATE C421M Scarabeo 50 2T (PA • Remove the fairing from behind. • Loosen and remove the two screws and collect the helmet hook. • Working on either side, loosen and remove the screw and keep the nut. • Remove the fuel tank plug and mixer oil tank plug and close the tanks openings with a clean rag.
  • Page 30 UPDATE Scarabeo 50 2T (PA C421M) • Remove the tie and release the tube. • Remove the underseat panel by moving it at the front and releasing it from the frame fasteners. • Remove the rags used to block off tanks openings and fit the relevant plugs.
  • Page 31 UPDATE C421M Scarabeo 50 2T (PA • Working on the right side, loosen and remove the screw, move aside the splash guard to collect the washer. • Move the fuel tank – mixer oil tank unit to the front. • Release the fuel line from the tie.
  • Page 32 UPDATE Scarabeo 50 2T (PA C421M) • Take a container of capacity equal to fuel tank. • Pinch the tank-pump hose, avoiding damages. • Position a clean rag under the fuel cock and release the tie on fuel tank-cock hose. •...
  • Page 33 UPDATE C421M Scarabeo 50 2T (PA • Remove the fuel tank – mixer oil tank unit. • Working on the left side, loosen and remove the screw, collect the washer. • Working on the right side, loosen and remove the screw, collect the washer.

  • Page 34: Chassis

    UPDATE Scarabeo 50 2T (PA C421M) 2.5. CHASSIS 2.5.1. REMOVING THE SEAT • Insert the key in the seat latch. • Turn the key anticlockwise. • Raise the seat. • Support the seat from below, loosen and remove the four screws. •...

  • Page 35: Removing The Passenger Grab Handle

    UPDATE C421M Scarabeo 50 2T (PA 2.5.2. REMOVING THE PASSENGER GRAB HANDLE • Insert the top case key in the top case latch. • Turn the key counter clockwise and press in. • Release the key and take it back to the starting position turning it clockwise by one step.
  • Page 36 UPDATE Scarabeo 50 2T (PA C421M) • Release and remove the three screws. • Remove the passenger grab handle complete with top case mount. • Collect the three washers. 2 - 35...

  • Page 37: Removing The Tail Light

    UPDATE C421M Scarabeo 50 2T (PA 2.5.3. REMOVING THE TAIL LIGHT • Remove the passenger grab handle, see (REMOVING THE PASSENGER GRAB HANDLE). • Remove the seat, see (REMOVING THE SEAT). • Release and remove the six screws. • Disconnect the brake, turn indicators and tail light connector and release ties and cable guides on the cable.
  • Page 38 UPDATE Scarabeo 50 2T (PA C421M) • Move the light to the front and collect the three washers. • Support the light, slide off the rear mudguard from below, keep connector. • Remove the tail light and mudguard. 2 - 37...

  • Page 39: Removing The Battery

    UPDATE C421M Scarabeo 50 2T (PA 2.5.4. REMOVING THE BATTERY • Working on either side, loosen and remove the screw. • Slide off the central panel from the front end. • Remove the breather hose. • Remove the two fuse carriers off their seats. 2 - 38...
  • Page 40 UPDATE Scarabeo 50 2T (PA C421M) • Loosen and remove the screw and completely open the battery door. • Slide off the battery from the front end. • Loosen and remove the screw on negative terminal and remove the terminal. •...

  • Page 41: Removing The Lower Shield

    UPDATE C421M Scarabeo 50 2T (PA 2.5.5. REMOVING THE LOWER SHIELD • Working on either side, loosen and remove the two screws. • Working on either side, loosen and remove the two screws. • Release and remove the two screws. 2 - 40...
  • Page 42 UPDATE Scarabeo 50 2T (PA C421M) • Working on either side, loosen and remove the two screws. • Remove the lower shield. 2 - 41...

  • Page 43: Removing The Exhaust System

    UPDATE C421M Scarabeo 50 2T (PA 2.5.6. REMOVING THE EXHAUST SYSTEM • Position the vehicle on the centre stand. • Remove the lower shield, see (REMOVING THE LOWER SHIELD). • Unscrew and remove the two nuts on exhaust manifold. Working on the right side, loosen and remove the two screws.
  • Page 44 UPDATE Scarabeo 50 2T (PA C421M) • Remove the clamp and the exhaust gas recovery tube. • Slide off the exhaust pipe from below. 2 - 43...

  • Page 45: Electric System

    UPDATE C421M Scarabeo 50 2T (PA 2.6. ELECTRIC SYSTEM 2.6.1. WIRING DIAGRAM 2 - 44...
  • Page 46 UPDATE Scarabeo 50 2T (PA C421M) Key: Cable colour: Multiple connectors Orange Instrument panel Light blue Oil level warning light Blue Dashboard bulbs White High beam warning light Yellow Direction indicator warning light Grey Fuel level gauge Brown Check diode Black Key-operated switch Warning horn...
  • Page 47 G.Galilei, 1 30033 Noale (VE) Italy tel. +39 041.5829111 fax +39 041.5829190 www.aprilia.com www.serviceaprilia.com...

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