APRILIA Scarabeo 500 Workshop Manual
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APRILIA Scarabeo 500 Workshop Manual

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Scarabeo 500
1325 6
05/2006-00
workshopmanual

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Summary of Contents for APRILIA Scarabeo 500

  • Page 1 Scarabeo 500 1325 6 05/2006-00 workshopmanual...
  • Page 2 INTRODUCTION SCARABEO 500 INTRODUCTION 0 - 1...
  • Page 3 INTRODUCTION SCARABEO 500 SUMMARY 0.1. INTRODUCTION ............................. 3 0.1.1. FOREWORD............................3 0.1.2. REFERENCE MANUALS........................4 0.1.3. ABBREVIATIONS/SYMBOLS/CONVENTIONS..................5 0 - 2...

  • Page 4: Introduction

    This manual provides the information required for normal servicing. This publication is intended for use by aprilia Dealers and their qualified mechanics; many concepts have been omitted on purpose as their inclusion would be superfluous. Since complete mechanical explanations have not been included in this manual, the reader must be familiar with basic notions of mechanics, as well as with basic repair procedures.

  • Page 5: Reference Manuals

    INTRODUCTION SCARABEO 500 0.1.2. REFERENCE MANUALS OWNER'S MANUALS aprilia part# (description) 8181030 8181031 8181032 SPARE PARTS CATALOGUE aprilia part# (description) 6836 CHASSIS WORKSHOP MANUAL aprilia part# (description) 8181020 8181021 8181022 8181023 8181024 ENGINE TECHNICAL MANUAL aprilia part# (description) 8140868 8140869...

  • Page 6: Abbreviations/Symbols/Conventions

    INTRODUCTION SCARABEO 500 0.1.3. ABBREVIATIONS/SYMBOLS/CONVENTIONS = number < = less than > = greater than ≤ = less than or equal to ≥ = more than or equal to = approximately ∞ = infinity °C = degrees Celsius (centigrade) °F = degrees Fahrenheit ±...
  • Page 7 INTRODUCTION SCARABEO 500 RIGHT SIDE = right side = Society of Automotive Engineers TEST = diagnostic check T.B.E.I. = crown-head Allen screw T.C.E.I. = cheese-head Allen screw T.E. = hexagonal head T.P. = flat head screw = Twin Spark Ignition...
  • Page 8 GENERAL INFORMATION SCARABEO 500 GENERAL INFORMATION 1 - 1...

  • Page 9: Table Of Contents

    GENERAL INFORMATION SCARABEO 500 SUMMARY 1.1. STRUCTURE OF THE MANUAL........................3 1.1.1. CONVENTIONS USED IN THE MANUAL ..................... 3 1.1.2. SAFETY WARNINGS..........................4 1.2. GENERAL RULES............................5 1.2.1. BASIC SAFETY RULES......................... 5 1.3. DANGEROUS ELEMENTS ..........................8 1.3.1. WARNINGS ............................8 1.4.

  • Page 10: Structure Of The Manual

    GENERAL INFORMATION SCARABEO 500 1.1. STRUCTURE OF THE MANUAL 1.1.1. CONVENTIONS USED IN THE MANUAL • This manual is divided in sections and subsections, each covering a set of the most significant components. Refer to the index of sections when consulting the manual.

  • Page 11: Safety Warnings

    GENERAL INFORMATION SCARABEO 500 1.1.2. SAFETY WARNINGS The following precautionary warnings are used throughout this manual in order to convey the following messages: Safety warning. This symbol appears, whether in the manual or on the vehicle itself, to indicate a personal injury hazard.

  • Page 12: General Rules

    GENERAL INFORMATION SCARABEO 500 1.2. GENERAL RULES 1.2.1. BASIC SAFETY RULES CARBON MONOXIDE Should it be necessary to perform some operations with the vehicle running, make sure to work outdoors or in a well- aerated room. Avoid starting the engine indoors.
  • Page 13 GENERAL INFORMATION SCARABEO 500 DANGER Take care not to spill coolant onto hot engine parts and exhaust system. It may ignite and produce invisible flames. Wear latex gloves when servicing. Although toxic, it has a sweet taste that might attract animals. Never leave coolant in open container or in a position easily reachable by animals.
  • Page 14 NOTE All bearings must rotate freely with no hard spots or noise. Replace any bearings that do not meet these requirements. Use ORIGINAL aprilia SPARE PARTS only. Use the specified lubricants and consumables. Where possible, lubricate a part before assembly.

  • Page 15: Dangerous Elements

    GENERAL INFORMATION SCARABEO 500 1.3. DANGEROUS ELEMENTS 1.3.1. WARNINGS FUEL DANGER The fuel used to operate engines is highly flammable and becomes explosive under particular conditions. Refuelling and engine service should take place in a well-ventilated area with the engine stopped.
  • Page 16 GENERAL INFORMATION SCARABEO 500 BRAKE FLUID NOTE This vehicle is fitted with front and rear disc brakes. Each braking system is operated by an independent hydraulic circuit. The information provided below applies to both braking systems. DANGER Do not use the vehicle in case brakes are worn out or do not work properly. The brakes are the parts that most ensure your safety and for this reason they must always be perfectly working.
  • Page 17 GENERAL INFORMATION SCARABEO 500 COOLANT DANGER Coolant is toxic when ingested, contact with eyes or skin may cause irritation. In the event of contact with your skin or eyes, rinse repeatedly with abundant water and seek medical advice. In the event of ingestion, induce vomiting, rinse mouth and throat with abundant water and seek medical advice immediately.

  • Page 18: Running-In

    After the first 1000 km (621 mi), have the checking operations indicated in the column "After running- in" carried out by an aprilia Authorised Dealer, see REGULAR SERVICE INTERVALS CHART, in order to avoid hurting yourself or other people and/or damaging the vehicle.

  • Page 19: Vehicle Identification

    GENERAL INFORMATION SCARABEO 500 1.5. VEHICLE IDENTIFICATION 1.5.1. POSITION OF THE SERIAL NUMBERS These numbers are necessary for vehicle registration. NOTE Altering the vehicle identification numbers is a legal offence. Altering the frame number invalidates the warranty. FRAME NUMBER The frame number is stamped on the front frame, open the glove compartment and remove the protection cover to be able to read it.
  • Page 20 GENERAL TECHNICAL INFORMATION SCARABEO 500 GENERAL TECHNICAL INFORMATION 2 - 1...
  • Page 21 GENERAL TECHNICAL INFORMATION SCARABEO 500 SUMMARY 2.1. TECHNICAL INFORMATION .......................... 3 2.1.1. TECHNICAL DATA ..........................3 2.1.2. SCHEDULED MAINTENANCE CHART....................5 2.1.3. LUBRICANT CHART..........................7 2.1.4. TIGHTENING TORQUE SETTINGS ...................... 8 2.1.5. ARRANGEMENT OF THE MAIN ELEMENTS ..................13 2.1.6.

  • Page 22: Technical Information

    GENERAL TECHNICAL INFORMATION SCARABEO 500 2.1. TECHNICAL INFORMATION 2.1.1. TECHNICAL DATA DIMENSIONS Max. Length 2263 mm (89.1 in.) Max. Width 790 mm (31.1 in.) Max. height (headlight fairing included) 1419 mm (55.9 in.) Seat height 785 mm (30.9 in.) Wheelbase 1535 mm (60.4 in.)
  • Page 23 GENERAL TECHNICAL INFORMATION SCARABEO 500 BRAKES Front Disc - Ø 260 mm (10.236 in) - with hydraulic transmission Rear Twin disc - front Ø 260 mm (10.236 in) / rear Ø 240 mm (9.449 in) WHEEL RIMS Type in light alloy Front 16"...

  • Page 24: Scheduled Maintenance Chart

    GENERAL TECHNICAL INFORMATION SCARABEO 500 2.1.2. SCHEDULED MAINTENANCE CHART Suitable maintenance ensures optimum operating conditions and performance and it is essential for vehicle long life. EVERY 2 years Coolant - change Brake fluid - change At 1000 km (621 mi)
  • Page 25 GENERAL TECHNICAL INFORMATION SCARABEO 500 At 20000 km (12427 mi), 40000 km (24855 mi), 60000 km (37282 mi) and at 80000 km (49710 mi) Safety fastening points - check Driven pulley bush Spark plug - change Belt - change Throttle control - adjust Air filter - check Belt comp.air filter - check...

  • Page 26: Lubricant Chart

    GENERAL TECHNICAL INFORMATION SCARABEO 500 2.1.3. LUBRICANT CHART LUBRICANT PRODUCT Engine oil RECOMMENDED: 4T FORMULA RACING, SAE 5W - 40. As an alternative to recommended fluids, top brand oils meeting or exceeding A.P.I. specifications can be used. Transmission fluid RECOMMENDED: GEAR SYNTH, SAE 75W - 90.

  • Page 27: Tightening Torque Settings

    GENERAL TECHNICAL INFORMATION SCARABEO 500 2.1.4. TIGHTENING TORQUE SETTINGS DESCRIPTION BRAKING SYSTEM Rear brake master cylinder to handlebar fastening 2 TCEI screw M6x25 Throttle control to front brake master cylinder fastening 2 TCEI screw M6x25 TBEI screw M5x16 RH dimmer switch to brake master cylinder fastening...
  • Page 28 GENERAL TECHNICAL INFORMATION SCARABEO 500 DESCRIPTION FRONT SUSPENSION TIGHTEN TO 25 Nm THEN Fork nut SLACKEN AND TAKE TO 10 Nm Fork lock nut Fork hub fastening Screw Front mudguard fastening TE screw M6x16 HANDLEBAR ASSY Handlebar to fork fastening...
  • Page 29 GENERAL TECHNICAL INFORMATION SCARABEO 500 DESCRIPTION ELECTRIC SYSTEM ASSY Linear switch to frame fastening TE screw M5X16 Control unit to frame fastening TE screw M5X16 H.T. coil to coil support bracket fastening TE screw M3X20 Relay support bracket to frame fastening...
  • Page 30 GENERAL TECHNICAL INFORMATION SCARABEO 500 DESCRIPTION CENTRE CHASSIS ASSY Case to frame fastening 6 TBEI screw M6X16 Rh/Lh platform to Rh/Lh rider platform connection plate 4 TBEI screw M5X12 fastening Rh/Lh platform to radiator cowl fastening 3 TBEI screw M5x16...
  • Page 31 GENERAL TECHNICAL INFORMATION SCARABEO 500 DESCRIPTION FRONT CHASSIS ASSY SELF-TAPPING Logo to cover fastening screw 3.9X14 Ignition switch cover to shield fastening Washers for shafts Rh/Lh turn indicator to cover fastening TCB screw M4X12 Rh leg guard fastening TCB screw 4.2X16...

  • Page 32: Arrangement Of The Main Elements

    GENERAL TECHNICAL INFORMATION SCARABEO 500 2.1.5. ARRANGEMENT OF THE MAIN ELEMENTS Key: Expansion tank Coolant expansion tank cap Integrated brake fluid reservoir Air filter Transmission cover Left passenger footpeg Centre stand Side stand Spark plug 10. Central inspection cover 11. Warning horn...
  • Page 33 GENERAL TECHNICAL INFORMATION SCARABEO 500 Key: Passenger grab handle Front brake fluid reservoir Seat release lever Fuel tank filler plug Fuel tank Battery Auxiliary fuse carrier Main fuse carrier Right passenger footpeg 10. Engine oil level / filler plug 2 - 14...

  • Page 34: Instrument Panel Operation

    GENERAL TECHNICAL INFORMATION SCARABEO 500 2.1.6. INSTRUMENT PANEL OPERATION Turn the ignition key to , on the multifunction LCD all segments activate (in this way a check routine of the components is performed) and the last function set before vehicle stopped is displayed.
  • Page 35 GENERAL TECHNICAL INFORMATION SCARABEO 500 TRIP METER RESET From the trip meter function, hold the MODE button for more than 3 seconds to reset it. SELECTING KM OR MILES From the battery function, hold the MODE button for more than 10 seconds to toggle between Km and miles reading both for odometer and tachometer (if on the display).
  • Page 36 GENERAL TECHNICAL INFORMATION SCARABEO 500 TRIP RESET TRIP 1/TRIP 2 • Press and hold (MODE) button (1) for more than three seconds when selected TRIP meter is displayed. NOTE The displayed function will be reset. The warning lights should be visible even when under direct sunlight.

  • Page 37: Scheduled Maintenance

    GENERAL TECHNICAL INFORMATION SCARABEO 500 2.2. SCHEDULED MAINTENANCE 2.2.1. BRAKING SYSTEM DANGER It is fundamental that air is bled off the hydraulic circuit after the brakes have been refitted and the braking system has been restored to its standard operating conditions, since it would be very dangerous for the vehicle and the rider not to do so.
  • Page 38 GENERAL TECHNICAL INFORMATION SCARABEO 500 BLEEDING THE REAR BRAKE • Remove the rubber protection cap from bleed valve (2). • Slide a clear plastic tube onto rear calliper bleed valve (2) and set the other end of the tube in a collector tank.

  • Page 39: Air Filter

    GENERAL TECHNICAL INFORMATION SCARABEO 500 2.2.2. AIR FILTER To clean the filtering element it is necessary to remove it from the vehicle. REMOVAL • Position the vehicle on the centre stand. • Unscrew and remove the nine screws (1). •...

  • Page 40: Coolant

    GENERAL TECHNICAL INFORMATION SCARABEO 500 2.2.3. COOLANT CHECKING AND TOPPING UP WARNING Wait for the engine to cool down before checking or topping up coolant level. • Stop the engine and wait until it has cooled down. NOTE Position the vehicle on firm and flat ground.

  • Page 41: Transmission Fluid

    GENERAL TECHNICAL INFORMATION SCARABEO 500 2.2.4. TRANSMISSION FLUID NOTE Only use recommended oil, see (LUBRICANT CHART) • Ride for a few kilometres to warm up engine to operating temperature then stop the engine. CHECK • Position the vehicle on firm and flat ground.
  • Page 42 GENERAL TECHNICAL INFORMATION SCARABEO 500 CHANGE • Position the vehicle on firm and flat ground. • Position the vehicle on the centre stand. WARNING Allow several minutes for the engine and exhaust system to cool down. • Unscrew and extract the plug/dipstick (1).

  • Page 43: Engine Oil

    GENERAL TECHNICAL INFORMATION SCARABEO 500 2.2.5. ENGINE OIL CHECKING AND TOPPING UP NOTE Only use recommended oil, see (LUBRICANT CHART) When topping up the engine oil, never exceed the "MAX" level. CHECK • Position the vehicle on firm and flat ground.
  • Page 44 GENERAL TECHNICAL INFORMATION SCARABEO 500 CHANGING ENGINE OIL AND OIL FILTER NOTE Position the vehicle on firm and flat ground. • Position the vehicle on the centre stand. WARNING Allow several minutes for the engine and exhaust system to cool down.
  • Page 45 FUEL SYSTEM SCARABEO 500 FUEL SYSTEM 3 - 1...
  • Page 46 FUEL SYSTEM SCARABEO 500 SUMMARY 3.1. FUEL TANK ..............................3 3.1.1. FUEL SUPPLY SYSTEM DIAGRAM...................... 3 3.1.2. REMOVING THE TANK ......................... 4 3.2. AIR FILTER ..............................6 3.2.1. REMOVING THE AIR BOX ........................6 3.3. DIAGNOSIS..............................8 3.3.1. AXONE..............................8...

  • Page 47: Fuel Tank

    FUEL SYSTEM SCARABEO 500 3.1. FUEL TANK 3.1.1. FUEL SUPPLY SYSTEM DIAGRAM Key: Fuel tank Tank plug Fuel level sensor Fuel pump Fuel pump ring nut seal Fuel pump ring nut Heat shield Washer Plate Rubber block Clip M6 Flanged Hex.screw M6X20 Fuel line D5.5X10...

  • Page 48: Removing The Tank

    FUEL SYSTEM SCARABEO 500 3.1.2. REMOVING THE TANK • Remove the front cover, see (REMOVING THE FRONT COVER). • Remove the tail guard, see (REMOVING THE TAIL GUARD) • Remove footboard (REMOVING FOOTBOARD) • Remove the leg guards, see (REMOVING THE FORK LEGS) •...
  • Page 49 FUEL SYSTEM SCARABEO 500 • Working on either side, loosen and remove the two screws securing the front lower support crosspiece. • Remove the crosspiece. • Loosen and remove the tank front retaining screw. • Loosen and remove the tank rear retaining screw.

  • Page 50: Air Filter

    FUEL SYSTEM SCARABEO 500 3.2. AIR FILTER 3.2.1. REMOVING THE AIR BOX • Working on the left side, loosen and remove the two side securing screws from rear mudguard and collect both washers. NOTE On refitting, pay special attention to the length of the securing screws as the rear screw is shorter.
  • Page 51 FUEL SYSTEM SCARABEO 500 • Loosen the screw of the air filter inner support. • Loosen the intake manifold clamp. • Remove the bleeder. • Remove the air box. 3 - 7...

  • Page 52: Diagnosis

    FUEL SYSTEM SCARABEO 500 3.3. DIAGNOSIS 3.3.1. AXONE SYMBOL SCREEN ENGINE PARAMETER READING DEVICE STATUS (in general they are “On – Off” values) DEVICES ACTIVATION ERRORS DISPLAY ADJUSTABLE PARAMETERS FREEZE FRAME APPROXIMATE UNIT OF SCREEN DESCRIPTION NOTES VALUES MEASURE Mapping code with reversed figures. If...
  • Page 53 FUEL SYSTEM SCARABEO 500 APPROXIMATE UNIT OF SCREEN DESCRIPTION NOTES VALUES MEASURE ENGINE PARAMETER READING Water temperature °C Measured with sensor on engine Temperature measured engine intake (sensor in throttle housing). Note Air temperature °C that the temperature at the instrument...
  • Page 54 FUEL SYSTEM SCARABEO 500 APPROXIMATE UNIT OF SCREEN DESCRIPTION NOTES VALUES MEASURE DEVICE STATUS Engine status OFF / rotating Engine stationary or in rotation Synchronized detects Synchronized/Not Signal panel correct synchronisation (by way of sync crankshaft speed sensor) Idle/full load...
  • Page 55 FUEL SYSTEM SCARABEO 500 APPROXIMATE UNIT OF SCREEN DESCRIPTION NOTES VALUES SIZE ERRORS DISPLAY In the event of an interruption in the Throttle throttle position sensor signal In the event of an interruption in the Pressure atmospheric pressure sensor signal...
  • Page 56 ENGINE SCARABEO 500 ENGINE 4 - 1...
  • Page 57 ENGINE SCARABEO 500 SUMMARY 4.1. ENGINE ................................3 4.1.1. REMOVING THE ENGINE FROM THE FRAME..................3 4.1.2. INSTALLING THE ENGINE ......................... 17 4 - 2...
  • Page 58 ENGINE SCARABEO 500 4.1. ENGINE 4.1.1. REMOVING THE ENGINE FROM THE FRAME • Position the vehicle on the centre stand. • Remove the tail guard, see (REMOVING THE TAIL GUARD) • Remove the helmet compartment, see (REMOVING THE HELMET COMPARTMENT).
  • Page 59 ENGINE SCARABEO 500 • Slide the hose out. NOTE Remove the expansion tank plug to let the coolant flow out. • Drain the system. • Working on the right side, loosen and remove the two side securing screws from rear mudguard and collect both shims.
  • Page 60 ENGINE SCARABEO 500 • Loosen and remove the securing screw from the oil recovery flange. • Slide the flange out of its seat. • Loosen the screw of the air filter inner support. • Loosen the intake manifold clamp. •...
  • Page 61 ENGINE SCARABEO 500 • Remove the air box. • Set up the lift hoist and fasten the vehicle suitably with the lifting slings. • Loosen and remove the upper securing screw of the right shock absorber and collect the nut.
  • Page 62 ENGINE SCARABEO 500 • Loosen and remove the lower securing screw of the left shock absorber and collect the nut. • Move the shock absorber away • Loosen the adjusters and slide throttle cables out. • Remove air temperature sensor.
  • Page 63 ENGINE SCARABEO 500 NOTE Before proceeding with the operations, take a container of adequate capacity to collect possible coolant spillage. • Loosen the thermostatic valve clamp. • Remove the spark plug cap. • Remove the injector control sensor. • Slide the fuel lines out.
  • Page 64 ENGINE SCARABEO 500 • Loosen and remove the securing screw of the fuel lines and collect the washer. • Disconnect the coolant temperature sensor. • Remove the clamp. • Disconnect the lambda sensor connector. 4 - 9...
  • Page 65 ENGINE SCARABEO 500 • Disconnect the stepper motor connector. • Disconnect the throttle position sensor. • Loosen and remove the securing screw of the ground wires. • Open cable guide • Release the oil pressure sensor cable from the cable guide.
  • Page 66 ENGINE SCARABEO 500 • Disconnect the oil pressure sensor. • Working on both sides, loosen and remove the side securing screw. • Slightly lift the central fairing. • Remove and disconnect the generator connector. • Loosen the exhaust manifold clamp.
  • Page 67 ENGINE SCARABEO 500 • Loosen and remove the securing screw from the exhaust pipe clamp. • Push in the exhaust and remove the upper pin securing the clamp. • Loosen and remove the securing screw from the exhaust pipe. •...
  • Page 68 ENGINE SCARABEO 500 • Have an assistant apply the rear brake while you loosen and remove the rear securing nut from the plate. • Loosen and remove the two front securing nuts from the plate. • Remove the support plate.
  • Page 69 ENGINE SCARABEO 500 NOTE Place a suitable support on the vehicle lower side. • Loosen and remove the five screws securing the wheel. • Remove the wheel. • Loosen and remove the securing screw from the rear brake line, collect the spacer.
  • Page 70 ENGINE SCARABEO 500 • Loosen and remove the securing nut from the positive cable. • Release the positive cable. • Working on the right side, loosen and remove the securing nut from the swinging arm shaft and collect the washer.
  • Page 71 ENGINE SCARABEO 500 • Loosen and remove the securing nut from the connecting rod and collect the washer and the silent block. • Loosen the pin and collect the washer. • Release slings from hoist supporting the vehicle rear end and remove the frame from the engine.
  • Page 72 ENGINE SCARABEO 500 4.1.2. INSTALLING THE ENGINE • Move the frame bit by bit until fastening holes are aligned. • Fit the washer between swingarm shaft and frame during this procedure. • Working on the left side, fit the shaft.
  • Page 73 ENGINE SCARABEO 500 • Set the silent block with washer and tighten the nut. • Set the positive cable. • Tighten the nut. • Fit the protection element. • Fit the rear brake calliper. • Tighten the two securing screws on the rear brake calliper.
  • Page 74 ENGINE SCARABEO 500 • Set the rear brake line guide and spacer, then tighten its screw. • Fit the wheel. • Tighten the five wheel screws. • Fit the support plate. • Fit and tighten the two front nuts on support plate.
  • Page 75 ENGINE SCARABEO 500 • Fit the shim. • Fit the plate rear nut. • Have an assistant apply the rear brake while you tighten the rear securing nut on the plate. • Fit the cap. • Fit the safety split pin.
  • Page 76 ENGINE SCARABEO 500 • Fit the tailpipe. • Fit and tighten the securing screw on the exhaust pipe. • Fit and tighten the securing screw on the exhaust pipe clamp. • Push in the exhaust and fit the upper pin securing the clamp.
  • Page 77 ENGINE SCARABEO 500 • Working on both sides, fit and tighten the side securing screw. • Connect the oil pressure sensor. • Fit the oil pressure sensor cable. • Secure the two clamps. • Connect the throttle position sensor. 4 - 22...
  • Page 78 ENGINE SCARABEO 500 • Connect the stepper motor connector. • Connect the lambda sensor connector. • Fasten the clamp. • Connect the coolant temperature sensor. • Fit the fuel lines. 4 - 23...
  • Page 79 ENGINE SCARABEO 500 • Fit the hose stop washer and then fit and tighten the fuel lines retaining screw. • Fit the injector control sensor. • Fit the spark plug cap. • Fit the coolant hose. • Tighten the clamp on thermostatic valve.
  • Page 80 ENGINE SCARABEO 500 • Fit the air temperature sensor. • Fit throttle cables and tighten the adjusters. • Install the shock absorber. • Set the shock absorber screw and tighten the nut. 4 - 25...
  • Page 81 ENGINE SCARABEO 500 • Install the shock absorber. • Set the right shock absorber screw and tighten the nut. • Fit the air box. • Fit the bleeder. • Fit the intake manifold and tighten the clamp. 4 - 26...
  • Page 82 ENGINE SCARABEO 500 • Fit and tighten the screw on air filter internal support. • Fit the flange. • Fit and tighten the securing screw from the oil recovery flange. • Fit the mudguard. 4 - 27...
  • Page 83 ENGINE SCARABEO 500 • Working on the left side, fit and tighten the two side securing screws on rear mudguard with washers. • Working on the right side, fit and tighten the two side securing screws on rear mudguard with shims.
  • Page 84 ENGINE SCARABEO 500 • Set the tail guard, see (REMOVING THE TAIL GUARD) 4 - 29...
  • Page 85 CYCLE PARTS SCARABEO 500 CYCLE PARTS 5 - 1...
  • Page 86 CYCLE PARTS SCARABEO 500 SUMMARY 5.1. OUTER STRUCTURES........................... 3 5.1.1. REMOVING THE SEAT ......................... 3 5.1.2. REMOVING THE FRONT COVER ......................4 5.1.3. REMOVING THE TAIL GUARD ......................5 5.1.4. REMOVING THE HELMET COMPARTMENT ..................9 5.1.5. REMOVING THE FOOTREST ......................13 5.1.6.

  • Page 87: Outer Structures

    CYCLE PARTS SCARABEO 500 5.1. OUTER STRUCTURES 5.1.1. REMOVING THE SEAT To remove the seat you first need to raise it. To do this you can: either use the supplied remote control and press the button (1) to automatically open the seat.

  • Page 88: Removing The Front Cover

    CYCLE PARTS SCARABEO 500 5.1.2. REMOVING THE FRONT COVER • Position the vehicle on the centre stand. • Completely turn the handlebar to the right and remove the top screw. NOTE Proceed in the same way on the opposite side, turning handlebar to the left.

  • Page 89: Removing The Tail Guard

    CYCLE PARTS SCARABEO 500 5.1.3. REMOVING THE TAIL GUARD • Position the vehicle on the centre stand. • Working on either side, open the passenger footrest. • Working on either side, loosen and remove the three screws from footrests. NOTE The rear screw is longer than the front ones, ensure to refit it in the correct position.
  • Page 90 CYCLE PARTS SCARABEO 500 • Loosen and remove the two tail guard front screws. • Working on either side, loosen and remove the two side lower screws. • Loosen and remove the four screws from grab handle cover. • Remove the cover.
  • Page 91 CYCLE PARTS SCARABEO 500 • Loosen and remove the three screws securing the grab handle. NOTE The centre screw is longer than the side ones, ensure to refit it in the correct position. • Remove the tail light top cover.
  • Page 92 CYCLE PARTS SCARABEO 500 • Disconnect the three connectors. • Remove the tail guard together with tail light. 5 - 8...

  • Page 93: Removing The Helmet Compartment

    CYCLE PARTS SCARABEO 500 5.1.4. REMOVING THE HELMET COMPARTMENT • Raise the seat. • Loosen and remove the two battery cover screws. • Remove the battery cover. • Remove the tail guard, see (REMOVING THE TAIL GUARD) • Remove the seat, see (REMOVING THE SEAT) •...
  • Page 94 CYCLE PARTS SCARABEO 500 • Slide out cables from helmet compartment. • Loosen and remove the screw securing the helmet compartment light switch. • Disconnect connectors helmet compartment light switch. • Remove the helmet compartment light bulb. 5 - 10...
  • Page 95 CYCLE PARTS SCARABEO 500 • Loosen and remove the two front screws. • Working on either side, loosen and remove the side screws. • Loosen and remove the two rear screws. • Loosen and remove the screws securing helmet compartment to number plate.
  • Page 96 CYCLE PARTS SCARABEO 500 • Remove the helmet compartment. 5 - 12...

  • Page 97: Removing The Footrest

    CYCLE PARTS SCARABEO 500 5.1.5. REMOVING THE FOOTREST • Remove the tail guard, see (REMOVING THE TAIL GUARD) • Remove the inner front cover, see (REMOVING THE TANK) • Remove the centre tunnel, see (REMOVING THE TANK) • Loosen and remove the two bottom screws.

  • Page 98: Removing The Instrument Panel

    CYCLE PARTS SCARABEO 500 5.1.6. REMOVING THE INSTRUMENT PANEL • Remove the headlight, see (REMOVING THE HEADLIGHT). • Working on either side, loosen and remove the two screws securing the front instrument panel fairing. • Remove the front instrument panel fairing.

  • Page 99: Removing The Headlight

    CYCLE PARTS SCARABEO 500 5.1.7. REMOVING THE HEADLIGHT • Loosen and remove the securing screw from the headlight frame. • Remove the headlight frame. • Remove the top shell disengaging the tabs. WARNING Proceed with care. Do not damage the tabs and/or their seats.
  • Page 100 CYCLE PARTS SCARABEO 500 • Move aside the headlight and disconnect the connector. • Carefully remove the headlight avoiding damages. 5 - 16...

  • Page 101: Removing The Seat Releasing System

    CYCLE PARTS SCARABEO 500 5.1.8. REMOVING THE SEAT RELEASING SYSTEM • Remove central inspection cover, (REMOVING THE TAIL GUARD) • Release the control cable. • Release the control cable and the seat releasing cable. • Remove the connector. • Unscrew and remove the two screws.

  • Page 102: Exhaust System

    CYCLE PARTS SCARABEO 500 5.2. EXHAUST SYSTEM 5.2.1. REMOVING THE EXHAUST SYSTEM • Loosen the exhaust manifold clamp. • Loosen and remove the securing screw from the exhaust pipe clamp. • Push in the exhaust and remove the upper pin securing the clamp.
  • Page 103 CYCLE PARTS SCARABEO 500 • Remove the exhaust pipe. 5 - 19...

  • Page 104: Front Wheel

    CYCLE PARTS SCARABEO 500 5.3. FRONT WHEEL 5.3.1. FRONT WHEEL DIAGRAM Key: Wheel shaft Odometer sensor Right oil seal Right bearing Wheel Inner spacer Left bearing Left oil seal Brake discs Left spacer Right spacer NOTE Grease wheel shaft (1).

  • Page 105: Removing The Front Wheel

    CYCLE PARTS SCARABEO 500 5.3.2. REMOVING THE FRONT WHEEL • Working on either side, loosen and remove the two screws from brake calliper. • Slide off both callipers from the front brake discs. • Place the vehicle on the front stand (OPT).

  • Page 106: Rear Wheel

    CYCLE PARTS SCARABEO 500 5.4. REAR WHEEL 5.4.1. REAR WHEEL DIAGRAM Key: Complete wheel Split pin External spacer Screw Washer Washer Inner spacer Wheel hub Brake disc 5 - 22...

  • Page 107: Removing The Rear Wheel

    CYCLE PARTS SCARABEO 500 5.4.2. REMOVING THE REAR WHEEL • Working on the right side, loosen and remove the two side securing screws from rear mudguard and collect both shims. • Loosen the exhaust manifold clamp. • Loosen and remove the securing screw from the exhaust pipe clamp.
  • Page 108 CYCLE PARTS SCARABEO 500 • Remove the safety split pin. • Remove the cap. • Have an assistant apply the rear brake while you loosen and remove the rear securing nut from the plate. 5 - 24...
  • Page 109 CYCLE PARTS SCARABEO 500 • Loosen and remove the two front securing nuts from the plate. • Remove the support plate. NOTE Place a suitable support on the vehicle lower side. • Loosen and remove the five screws securing the wheel.

  • Page 110: Braking System

    CYCLE PARTS SCARABEO 500 5.5. BRAKING SYSTEM 5.5.1. BRAKING SYSTEM DIAGRAM 5 - 26...
  • Page 111 CYCLE PARTS SCARABEO 500 Key: Front right brake calliper Front left brake calliper Pads – set Kit pins + clip Bleeder Bleeder cap TCEI screw M8x35 Front brake line Front calliper brake force distributor line Delay valve Flanged Hex.screw M6X35 Brake line from m.

  • Page 112: Changing The Pads

    CYCLE PARTS SCARABEO 500 5.5.2. CHANGING THE PADS FRONT BRAKE • Remove the calliper, see (REMOVING THE FRONT WHEEL). • Unscrew and remove the central screw (1). WARNING These operations apply to both brake callipers. • Release the retainer (2).
  • Page 113 CYCLE PARTS SCARABEO 500 REAR BRAKE • Remove the rear wheel, see (REMOVING THE REAR WHEEL). • Remove the circlip. • Slide the pin. • Remove the spring. WARNING On spring is an arrow that should always be pointing in the direction of travel.

  • Page 114: Removing The Brake Force Distribution

    CYCLE PARTS SCARABEO 500 5.5.3. REMOVING THE BRAKE FORCE DISTRIBUTION • Remove the front cover, see (REMOVING THE FRONT COVER). • Loosen and remove the three screws securing the immobilizer control unit. • Move aside the immobilizer control unit keeping it connected to the wiring.

  • Page 115: Front Fork

    CYCLE PARTS SCARABEO 500 5.6. FRONT FORK 5.6.1. FRONT FORK DIAGRAM Key: Fork base tube Fork clamp screws O-ring Snap ring Seal plug Spring Damping rod Counter spring Buffer Left slider Dust seal Safety snap ring Seal Washer Bushing Left sleeve...

  • Page 116: Removing The Fork Legs

    CYCLE PARTS SCARABEO 500 5.6.2. REMOVING THE FORK LEGS • Support the vehicle front end using slings and a hoist. • Remove the front wheel, see (REMOVING THE FRONT WHEEL). • Loosen and remove the front brake line guide screw.
  • Page 117 CYCLE PARTS SCARABEO 500 • Slacken the two fork leg retaining screws. • Remove the top circlip (2). • Remove the outer sleeve (3) sliding it off from the bottom. 5 - 33...

  • Page 118: Draining Oil

    CYCLE PARTS SCARABEO 500 5.6.3. DRAINING OIL NOTE Before performing the following operations, prepare a container of suitable capacity. • Set the sleeve in a vice. WARNING The slider and sleeve assembly is filled with oil: do not turn it upside-down or excessively tilt it during disassembly.
  • Page 119 CYCLE PARTS SCARABEO 500 • Drain oil into the container pumping with the slider. 5 - 35...

  • Page 120: Disassembling The Fork

    CYCLE PARTS SCARABEO 500 5.6.4. DISASSEMBLING THE FORK • Drain oil, see (DRAINING OIL). • Set the slider in a vice with soft jaws (aluminium). • Unscrew and remove the lower screw (1), collect the washer. • Slide the slider off the sleeve and collect the bushing.
  • Page 121 CYCLE PARTS SCARABEO 500 • Remove the circlip (5) from sleeve. • Remove the oil seal (6) from sleeve. • Remove the washer (7) from sleeve. • Remove the shell (8) from sleeve. 5 - 37...

  • Page 122: Filling Oil

    CYCLE PARTS SCARABEO 500 5.6.5. FILLING OIL • Set the slider and sleeve assembly in a vice with soft jaws (aluminium). • Pour fork oil in the assembly. WARNING Do not reuse oil that was previously drained. • Insert the spring.
  • Page 123 CYCLE PARTS SCARABEO 500 • Move down plug (1) until it is possible to fit circlip (2). • Fit circlip (2). 5 - 39...

  • Page 124: Checking The Components

    CYCLE PARTS SCARABEO 500 5.6.6. CHECKING THE COMPONENTS OUTER SLEEVE • Inspect the sliding surface for scoring and/or scratching. Eliminate minor scoring with wet sand paper (grain size 1). • Replace the stanchion if badly scored. • Check for stanchion buckling using a dial gauge.

  • Page 125: Reassembling The Fork

    CYCLE PARTS SCARABEO 500 5.6.7. REASSEMBLING THE FORK • Set the sleeve in a vice with soft jaws (aluminium). • Fit spacer (1). WARNING Ensure that no foreign matter enters inside the sleeve and slider. NOTE Before refitting the seals and bushings, smear them with a film of fork oil.
  • Page 126 CYCLE PARTS SCARABEO 500 • Fit the dust seal. • Install the damper rod and the spring in slider. • Install slider with bushing (2) in sleeve. • Tighten bottom screw (3) with washer. • Fill with oil, see (FILLING OIL).
  • Page 127 COOLING SYSTEM SCARABEO 500 COOLING SYSTEM 6 - 1...
  • Page 128 COOLING SYSTEM SCARABEO 500 SUMMARY 6.1. COOLING SYSTEM ............................3 6.1.1. COOLING SYSTEM DIAGRAM ......................3 6.1.2. CHANGING THE COOLANT ......................... 4 6.1.3. REMOVING THE EXPANSION TANK ....................5 6 - 2...

  • Page 129: Cooling System Diagram

    COOLING SYSTEM SCARABEO 500 6.1. COOLING SYSTEM 6.1.1. COOLING SYSTEM DIAGRAM Key: Radiator Expansion tank Expansion tank support Head-radiator hose Pump-radiator hose Electric fan mount Electric fan Spacer bushing Top rubber block Bottom rubber block Clip M5 Flanged Hex.screw M5X12 Plug Washer 6.6X18X1.6...

  • Page 130: Changing The Coolant

    COOLING SYSTEM SCARABEO 500 6.1.2. CHANGING THE COOLANT DRAINING NOTE Before proceeding with the operations, take a container of adequate capacity to collect possible coolant spillage. • Loosen the clamp. • Slide the hose out. NOTE Remove the expansion tank plug to let the coolant flow out.

  • Page 131: Removing The Expansion Tank

    COOLING SYSTEM SCARABEO 500 6.1.3. REMOVING THE EXPANSION TANK • Drain cooling system, (CHANGING COOLANT). • Remove the front cover, see (REMOVING THE FRONT COVER). • Detach breather tube (3) from expansion tank. • Loosen and remove the top screw (1) from expansion tank.
  • Page 132 ELECTRICAL SYSTEM SCARABEO 500 ELECTRICAL SYSTEM 7 - 1...
  • Page 133 ELECTRICAL SYSTEM SCARABEO 500 SUMMARY 7.1. ELECTRIC COMPONENTS ..........................3 7.1.1. CHECKING THE ELECTRICAL COMPONENTS .................. 3 7.1.2. WIRING DIAGRAM ..........................5 7 - 2...

  • Page 134: Electric Components

    ELECTRICAL SYSTEM SCARABEO 500 7.1. ELECTRIC COMPONENTS 7.1.1. CHECKING THE ELECTRICAL COMPONENTS 7 - 3...
  • Page 135 ELECTRICAL SYSTEM SCARABEO 500 Key: Bank angle sensor 30A Starter relay 30A relay with diode Headlight Tail light Coil with cable and cap Main fuses Warning horn Voltage regulator 150A Starter relay 12V Battery Auxiliary fuses 7 - 4...

  • Page 136: Wiring Diagram

    ELECTRICAL SYSTEM SCARABEO 500 7.1.2. WIRING DIAGRAM 7 - 5...
  • Page 137 ELECTRICAL SYSTEM SCARABEO 500 Key: WIRE COLOUR CODING Multiple connectors Orange Speed sensor Light blue Oil pressure sensor Blue Instrument panel White Instr. panel Diag. Yellow Warning horn Grey Left dimmer switch Brown Rear stoplight switch Black Left dimmer switch 10.
  • Page 138 G.Galilei, 1 30033 Noale (VE) Italy tel. +39 041.5829111 fax +39 041.5801674 www.aprilia.com...

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