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APRILIA SCARABEO 50 I.E-100 4T - 2001, Workshop Manual, Page: 103 / 110

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APRILIA SCARABEO 50 I.E-100 4T - 2001 Workshop Manual Download Page 103

102

Release 00

2003-02

Scarabeo 50 I.E.-50/100 4T

ARRANGEMENT OF THE COMPONENTS

KEY

3) Serial connection 

12) Spark plug
13) Fuses
14) Battery
17) Injection relay 
18) Voltage regulator
20) Pressure sensor (not fitted as standard) 
22) Rear brake stoplight switch
23) Rear left direction indicator
24) Rear parking/brake lamp
26) Oil level switch 
31) Left dimmer switch
32) Horn
41) Front left direction indicator
42) High/low beam bulb (35/35W)
44) License plate lamp 

100

42

41

22

31

26

24

44

23

20

14

18

13

32

3

17

12

Summary of Contents for SCARABEO 50 I.E-100 4T - 2001

Page 1: ...workshopmanual www serviceaprilia com SCARABEO 50 I E 50 100 4T 1118 2 02 2003 00 8140696 UK...

Page 2: ...T 5652 Scarabeo 100 4T 6631 Scarabeo 50 IE 5601 aprilia s p a reserves the right to modify any of its mod els in any manner at any time This manual is protected by copyright in all countries Re produc...

Page 3: ...to your eyes If you should accidentally get brake fluid in your eyes flush immediately with a large quan tity of cool clear water and seek professional medical assistance immediately KEEP BRAKE FLUID...

Page 4: ...connecting any pipe cable etc mark each part with a number or distinguishing mark Each disconnected part must be marked clearly in order that it may be reas sembled in the same position as it was befo...

Page 5: ...ves of the connectors are firmly pressed together TIGHTENING TORQUES The table below shows tightening torques for screws and bolts with metric ISO threads as is used in this vehicle These are general...

Page 6: ...e vehicle NOTE When asking your Dealer for spare parts specify the spare parts code indicated on the SPARE PARTS IDENTIFICATION LABEL Write down the identification code in the space here below in orde...

Page 7: ...31 FUEL 31 DRAINING THE FUEL TANK 32 REMOVING THE FUEL PUMP FLANGE 32 CLEANING THE FUEL FILTER 32 DRAINING THE FUEL TANK 100 33 CLEANING THE FUEL FILTER 33 CHECKING THE FUEL LEVEL GAUGE UNIT 33 REMOV...

Page 8: ...Y 66 ADJUSTING THE BEARING PLAY 66 REMOVING THE FORK HEAD BEARINGS 67 FRONT FORK 68 REMOVING THE COMPLETE FORK 68 DISASSEMBLING THE LOWER FORK LEGS 68 REMOVING THE COMPLETE DAMPER 68 REAR SUSPENSION 6...

Page 9: ...in 100 50 mm 49 mm 2 in 1 9 in Starting electric 100 electric kick starter CAPACITIES Fuel reserve included Seats 1 l 0 2 gal 1 2 in the countries where this is allowed 2 100 Fuel reserve Engine oil 8...

Page 10: ...8 66 in with hydraulic transmission BRAKES Rear disc brake 190 mm 7 48 in with hydraulic transmission Rear 100 140 mm 5 51 in Rear Rear Spark advance 26 Spark advance 100 17 at 7500 rpm Standard spar...

Page 11: ...Y Front brake caliper fork fastening M8 23 16 96 Brake pump clamps fastening screw M6 10 7 37 Brake pump caliper pipe 18 13 27 Brake caliper bleeder cap 14 10 32 Front brake disc fastening screw M8 23...

Page 12: ...LY Front brake caliper fork fastening M8 23 16 96 Brake pump clamps fastening screw M6 10 7 37 Brake pump caliper pipe 18 13 27 Brake caliper bleeder cap 14 10 32 Front brake disc fastening screw M8 2...

Page 13: ...ASSEMBLY Fork clip wheel pin fastening screw M6 12 8 85 Front wheel pin nut M12 35 25 81 REAR WHEEL ASSEMBLY Rear wheel nut M16 130 95 88 FRONT BRAKE ASSEMBLY Front brake caliper fork fastening M8 23...

Page 14: ...5W or F A 20W an alternative FORK 5W or FORK 20W Should you wish for a performance somewhere between that offered by F A 5W and F A 20W or FORK 5W and FORK 20W these can be mixed as indicated below S...

Page 15: ...bearings Brake discs Accelerator operation Piston rings every 12 000 km 7 440 mi General vehicle operation Brake systems discs Cylinder cooling system every 20 000 km 12 400 mi outside cleaning Carbon...

Page 16: ...operations more frequently if you use the vehicle in rainy and dusty areas or on uneven ground Injector cleaning every 8 000 km 5 000 mi Front variator needle rollers and guides Wheels tyres and infla...

Page 17: ...ter oil net Valve clearance every 24 000 km 15 000 mi Brake systems Cylinder ventilation system every 24 000 km 15 000 mi Greasing rear brake cam Brake shoe wear Brakes oil every 2 years Engine oil fi...

Page 18: ...mbers under any circumstance This is illegal in all countries In addition alteration of the identification numbers invalidates the warranty FRAME NUMBER The frame number 1 is stamped on the central tu...

Page 19: ...ere required 11 Anti theft hook for the aprilia Body Guard armored cable 10 11 9 4 5 8 3 2 1 6 7 1 2 3 5 7 4 6 8 10 9 11 ARRANGEMENT OF THE MAIN ELEMENTS 100 KEY 1 Horn 2 Glove compartment 3 Fuse carr...

Page 20: ...on Check 14 Blue high beam warning light 15 Red 2 stroke oil reserve warning light 16 Green low beam warning light 100 17 Total miles odometer ARRANGEMENT OF THE INSTRUMENTS INSTRUMENTS AND INDICATORS...

Page 21: ...s not pull on the throttle cable and change the engine idle speed and that the throttle grip returns smoothly and automati cally to its idle position when released If it does not NOTE For the lubricat...

Page 22: ...ed at the edge of the grip see the illustration above To adjust the cable Place the vehicle on the center stand Pull back the rubber boot 1 Loosen the lock nut 2 Rotate the adjuster 3 in such a way as...

Page 23: ...following operations let the engine and the exhaust silencer cool down until they reach room temperature in order to avoid burns Handle the plastic and painted components with care and avoid scraping...

Page 24: ...plastic clamps Disconnect the rear light main connector 8 Completely remove the rear part of the fairing 7 Upon reassembly Position the rear part of the fairing in its seat see the last four steps in...

Page 25: ...d p 2 GENERAL SAFETY RULES Place the vehicle on the center stand Before carrying out the following operations let the engine and the exhaust silencer cool down until they reach room temperature in ord...

Page 26: ...e p 24 REMOVING THE FOOTBOARD Remove the lower shield see p 24 REMOVING THE LOWER SHIELD Remove the rubber gasket 3 from the ignition switch Unscrew and remove the two screws 4 Open the cover 5 of the...

Page 27: ...er stand Remove the two screws 6 and the two screws 5 Slightly lift the upper part of the handlebar cover to release two of the four slots Gently push down the lower part of the handlebar cover to rel...

Page 28: ...Unscrew the metal ring 2 and withdraw the speedom eter odometer cable 3 from the coupling Unscrew and remove the three screws 4 Supporting the handlebar cover 5 disconnect the connectors 6 Remove the...

Page 29: ...ach side NOTE Upon reassembly use new clips REMOVING THE FRONT MUDGUARD Carefully read p 2 GENERAL SAFETY RULES Remove the complete fork see p 68 REMOVING THE COMPLETE FORK Remove the two screws 12 Ho...

Page 30: ...Remove the cap of the mixer oil tank 6 Disconnect the fuel breather pipe 7 from the fuel tank Disconnect the drainage pipe 9 from the fuel bowl 8 Remove the fuel bowl 8 NOTE Disconnect the electric co...

Page 31: ...supports Unscrew and remove the 4 screws 5 Unscrew and remove the filler cap 6 Disconnect the drainage pipe 8 from the fuel bowl 7 Remove the fuel bowl 7 Pass the cabling complete with relay switches...

Page 32: ...n and avoid inhalation of fuel vapors Do not ever attempt to siphon fuel from one container to another using your mouth as suction for a siphon hose Gasoline is poisonous and carcinogenic and contains...

Page 33: ...delivery pipe sleeve fitted to the fuel flange After draining the tank replace the filler cap in correct position REMOVING THE FUEL FLANGE Carefully read p 31 FUEL TANK Drain the fuel tank completely...

Page 34: ...crew the filter 4 from the flange 3 NOTE Clean it with compressed air and refit the filter 1 3 2 CAUTION WARNING CHECKING THE FUEL LEVEL GAUGE UNIT For the checking of the fuel level gauge unit see p...

Page 35: ...es or cables Remove the fuel breather pipe 7 see the figure on page 33 Unscrew the screws 2 and 3 and lift the entire fuel tank with care Remove the three screws 4 to free the tank from the rear prote...

Page 36: ...ompletely see below DRAINING Check and if necessary wash the filter 2 and the filtering element with a fireproof solvent removing all deposits and foreign matter DRAINING Carefully read above MIXER OI...

Page 37: ...HE DRAINED OIL AWAY FROM CHILDREN Place the vehicle on the center stand Fill the mixer oil tank completely Carry out the automatic bleeding procedure as follows Turn the acceleration handlebar to the...

Page 38: ...ribed previously FUEL PUMP Completely drain the fuel tank see page 32 Disconnect the electric connection 5 on the fuel pump Remove the two screws 6 that fasten the pump support to the frame Remove the...

Page 39: ...ity to see any obstacle along the road while riding at night It is always advisable to reduce speed when riding during the night in such a way as to have the time necessary to avoid any obstacle and t...

Page 40: ...way from the electrical components Remove the front handlebar cover see p 26 REMOV ING THE FRONT HANDLEBAR COVER Unscrew and remove the screw 3 remove the spring 4 NOTE Upon reassembly make sure that...

Page 41: ...ly and with care to avoid damaging the lens Push the bulb 4 in slightly and rotate it counterclock wise Extract the bulb 4 from its seat NOTE Insert the bulb in the bulb socket carefully aligning the...

Page 42: ...e bulb since these may cause its overheating and consequent breakage If you touch the bulb with your bare hands remove any fingerprints with a clean cotton cloth dampened with alcohol in order to avoi...

Page 43: ...care when removing the protective cover so that you do not break the coupling tooth Remove the protective cover 2 NOTE When reassembling make sure the protective cover is correctly positioned in its h...

Page 44: ...ard contains the warning light bulbs the dashboard lighting bulbs To change the bulbs Remove the front handlebar cover see p 26 REMOV ING THE FRONT HANDLEBAR COVER WARNING LIGHT BULBS NOTE Extract the...

Page 45: ...itioning them incorrectly during the reassembly Extract the appropriate bulb socket Extract the bulb and replace it with one of the same type DASHBOARD LIGHTING BULBS NOTE Extract the bulb sockets one...

Page 46: ...care Do not force the electric cables Partially remove the dashboard 3 Support the dashboard in order to prevent it from accidentally falling down Disconnect the speedometer odometer cable 4 from the...

Page 47: ...eatly re duce their effectiveness Failure to heed these warn ings may lead to a serious accident with consequent risk of serious injury or even death NOTE This vehicle is equipped with front and rear...

Page 48: ...kes with separate hydraulic systems NOTE For the version with rear drum brake the following information refers to the front disc brake only As the pads wear out the brake fluid level in the reservoir...

Page 49: ...ses progressively to compensate for their wear Check the brake pad wear see p 50 CHECKING WEAR OF THE BRAKE PADS and the disc wear If the pads and or the disc do not need replacing Check the brake sys...

Page 50: ...til covering the glass completely but leave a space of 5 6 mm 0 20 0 23 in from the brake fluid reservoir rim When topping up never exceed the MAX level Top up to MAX only when new pads are installed...

Page 51: ...production of sparks from the caliper braking efficiency and safety will be seriously compromised This could lead to a crash with subsequent serious injury or death CHANGING THE BRAKE PADS Place the v...

Page 52: ...e the pads or the disc with brake fluid Put the free end of the transparent tube into a clear container 4 Slowly pull the brake lever 5 through its full travel two or three times then keep it in a ful...

Page 53: ...sliding out from the back in the direction shown by the arrow Brake caliper screw 1 tightening torque 19 53 ftlb 27 Nm After reassembly pull the front brake lever repeatedly and check the correct fun...

Page 54: ...aliper using your fingers Use work gloves to carrying out these operations Failure to obey this warning can cause serious injury Insert the brake caliper 2 on the disc and position it so that its fast...

Page 55: ...if there is insufficient lubricant or with contaminated or unsuitable lubricants since these will speed up the wear of moving parts and can cause irreparable damage CHANGING THE TRANSMISSION OIL DISPO...

Page 56: ...e inflation at room temperature at least once a week see p 8 TECHNICAL DATA Pressure measurement must always be carried out when the tires are cold as when the tires are warmed up pressure will increa...

Page 57: ...that there are not sidewall breaks nor cuts in the tread or sidewall Some of the original equipment tires for this vehicle are provided with wear indicators There are several kinds of wear indicators...

Page 58: ...g it Make sure that the vehicle is stable If it falls it may injure you or bystanders as well as damaging property and being damaged itself Have a helper steady the handlebar in the straight ahead pos...

Page 59: ...EMBLY Carefully read p 2 GENERAL SAFETY RULES A dirty disc soils the pads with consequent reduction of the braking efficiency Dirty pads must be replaced while dirty discs must be cleaned with a high...

Page 60: ...akes Always apply the brake lever several times before riding your vehicle Then try your vehicle in a parking lot or other safe area with little traffic to ensure that the brakes are working properly...

Page 61: ...ning torque 110Nm 79 56 ftlb Remove the tie wrap 4 and the cardboard 3 Release the rear brake lever 2 Extract the wheel 100 Remove the rear brake caliper see p 52 REMOVING THE REAR BRAKE CALIPER Extra...

Page 62: ...firmly and try to move it perpendicu larly to the normal direction of travel see figure If any play is detected check all of the fasteners attaching the mounting unit see p 73 ENGINE MOUNTING BUSHINGS...

Page 63: ...e on the center stand Remove the inspection cover see p 22 REMOVING THE INSPECTION COVER Remove the pipe 2 supplying fuel to the injector from its housing on the air filter cover 1 Unfasten and remove...

Page 64: ...screws 5 that fix the guard 6 to the engine Unscrew the screw 7 and lift the rear shock absorber Remove the clamp 10 Remove the whole air filter case 2 from the front NOTE On reassembly fit a new cla...

Page 65: ...o clean the filtering element it is necessary to remove it from the vehicle REMOVAL THE AIR FILTER Place the vehicle on the center stand Unscrew and remove the six screws 1 Remove the air filter cover...

Page 66: ...ose and remove the two screws 1 keeping the relative stop nust situated on the back Unloose the splash guard to air cleaner casing fixing screw 6 Remove clamp 2 from the air tube using a suitable tool...

Page 67: ...LD Proceed with care Handle the plastic and painted components with care and avoid scraping or damaging them Remove the snap in plug 2 Working through the hole 3 prevent the screw 4 from rotating with...

Page 68: ...bars so that they do not strain the wires and cables Withdraw and remove the rubber gasket 5 Unscrew and remove the lock nut 6 Unscrew and remove the adjusting nut 7 When removing the fork be careful...

Page 69: ...see p 57 FRONT WHEEL To disassemble the right lower fork leg 1 Remove the screw 3 Screw 3 tightening torque 24 Nm 17 36 ftlb Withdraw the right lower fork leg 1 Check the wear of the sealing ring 5 r...

Page 70: ...ent it from dropping during the removal of the shock absorber Remove the upper screw 1 and washer Upper screw tightening torque 50 Nm 36 17 ftlb Remove the lower screw 2 and washer Lower screw tighten...

Page 71: ...RAL SAFETY RULES Place the vehicle on the center stand Remove the tail see REMOVING THE TAIL Slide out the spark plug Disconnect the electric connectors of the starter motor 1 and generator 2 and 3 Di...

Page 72: ...abeo 50 I E 50 100 4T 7 8 9 10 Remove the connectors 7 of the throttle positioning sensor 8 temperature sensor 9 and air injector Remove the screw 10 that fastens the ground cable to the engine Remove...

Page 73: ...signals PROCEED WITH GREAT CARE The size and weight of the vehicle may cause it to tilt dangerously during lifting with the possibility of the whole vehicle tipping over PROCEED WITH CARE AND MAKE SU...

Page 74: ...HE FRAME After removing the engine mounting bushings support the vehicle chassis with the support 1 Position a support 1 height 300 mm 11 81 in under the central part of the frame Make sure that the v...

Page 75: ...rogen gas especially when it is being charged when you are charging a battery make sure that the room is properly ventilated Do not inhale the gases released during charging Do not permit any open fla...

Page 76: ...d p 74 BATTERY ACCESSING THE BATTERY Make sure that the ignition switch is set to Lift up the saddle Remove the battery cover 4 The battery is connected to the electrical cables Do not pull on the cab...

Page 77: ...battery see p 75 REMOVING THE BATTERY The battery gives off noxious and explo sive gases keep it away from flames sparks cigarettes and any other source of heat During recharging or use make sure that...

Page 78: ...eassembling the electrical cables must be fed into a position in which they are not crushed in any way The negative cable must not cross the positive terminal but must be positioned to the side betwee...

Page 79: ...h a new fuse having the same amperage rating If you replace the fuse and it blows again immedi ately there is a serious problem with the electrical system of your vehicle Do not attempt to continue us...

Page 80: ...diagram 83 Stoplight circuit and starter circuit 87 Direction indicator circuit and horn circuit 89 Direction indicator circuit and horn circuit 100 90 Lighting circuit 91 Lighting circuit 100 92 Dash...

Page 81: ...ions C IF NO VOLTAGE REACHES THE LOADS UNDER DIRECT CURRENT green red cables Check the fuse and if necessary replace it Check the ground connections on regulator flywheel battery and fuse Check the ba...

Page 82: ...THE LOADS UNDER DIRECT CURRENT green red cables Check the fuse and if necessary replace it Check the ground connections on regulator flywheel battery and fuse Check the battery see below Check the ge...

Page 83: ...f the relay 5 Upon reassembly make sure that the electric con nector 4 is correctly coupled Energize 12V the two internal male terminals 1 2 Using an ohmmeter tester check the continuity be tween the...

Page 84: ...erature sensor 7 Oil pump 8 Fuel injector 9 Air injector 10 Fuel pump 11 H T coil 12 Spark plug 20 Pressure sensor not fitted as standard 34 Injection check warning light V R 7 5A FUSE B Ar N 1 21 20...

Page 85: ...R Using an ohmmeter tester check the resistance values between the two terminals from the injector side 1 Correct value 1 8 1 1 TROUBLESHOOTING Check the efficiency of the spark plug cap Using an ohmm...

Page 86: ...ize the pump 12VDC taking care to respect polarity and check that the resulting fuel flow is sufficient CHECKING THE OIL PUMP Using an ohmmeter tester check the resistance values between the two termi...

Page 87: ...element Try replacing the sensor with a new and operational one CHECKING THE TEMPERATURE SENSOR Disconnect the connector and use an ohmmeter to measure the resistance between the two terminals from th...

Page 88: ...switch see below Check the rear stoplight switch see below B STOPLIGHT DOESN T COME ON Check the bulb and the bulb socket Check the cable connections Check the general power supply circuit Check the...

Page 89: ...en the other two terminals 87 30 Correct value with relay energized 0 Correct value with relay not energized CHECKING THE STARTER MOTOR Directly energize the starter motor 12 VDC The starter motor sho...

Page 90: ...ata of the bulbs Check the battery Replace the flasher TEST DATA DIRECTION INDICATOR SWITCH Check the bulb efficiency Disconnect the left dimmer switch connector Using the ohmmeter function of the mul...

Page 91: ...lbs Check the battery Replace the flasher TEST DATA DIRECTION INDICATOR SWITCH Check the bulb efficiency Disconnect the left dimmer switch connector Using the ohmmeter function of the multimeter check...

Page 92: ...ht all glass 12V 1 2W W2x4 6 d License plate light bulb 12V 5W TROUBLESHOOTING A ONE BULB DOESN T WORK Check the bulb Make sure that there is voltage on the bulb socket terminals Check the harness con...

Page 93: ...ning light 12V 1 2 W Dashboard light bulbs 12V 1 2 W Low high beam bulb 12V 35 35 W TROUBLESHOOTING A ONE BULB DOESN T WORK Check the bulb Make sure that there is voltage on the bulb socket terminals...

Page 94: ...NG DIAGRAM DASHBOARD LIGHT CIRCUIT V R POSITIVE UNDER KEY STARTER BUTTON Bl G R Vi 35 33 26 27 39 Arrangement of the components see p 96 97 26 Oil level switch 27 Control diode 33 Fuel level sensor 35...

Page 95: ...he gray green and the blue cable on the main system side If the battery has 13 V 0 5 V the instrument should read 4 4 Connect a 100 2 W resistance between the gray green and the blue cable on the main...

Page 96: ...E 2 STROKE OIL LEVEL SENSOR Disconnect the cables which connect it to the system and remove it from the tank Using the ohmmeter function of the multimeter attach the multimeter leads to the sensor cab...

Page 97: ...G M G R N G Bi V R Bi R V Ro M G Bi G B G Ar N R N N N V B Ar Ar Bi BLUE GREEN ORANGE ORANGE WHITE G V Ar B R M R N V R Bi B Gr V Bi R G Gr B R B N B N R Bi B Gr G B B Bi Az R V R B Vi Vi Az Az B C Ar...

Page 98: ...23 Rear left direction indicator 24 Rear parking light stoplight bulb 25 Rear right direction indicator 26 Oil level switch 27 Control diode 28 Right dimmer switch 29 Key switch 30 Flasher 31 Left dim...

Page 99: ...V R Ar OFF LOCK 38 19 Gr B R B N B N R Bi B Gr Az Az G N V Bi N 18 38 G R G R V R V G 38 17 V G B R Az G Az G B R V G 14 16 15 38 Gr V B Gr V B 38 13 V R V G V R V G 10 9 B G R R 7 5 A Ar R R R N 7 8...

Page 100: ...rection indicator 17 Right dimmer switch 18 Left dimmer switch 19 Key switch 23 Dashboard 25 Low beam warning light 26 Dashboard lights 27 Fuel level device 29 High beam warning light 30 Direction ind...

Page 101: ...Az N B V R R Az Bi B B G G R Bi G Bi Bi N Bi R Gr V B G Gr V R Gr V B R Az LOCK OFF V R ON V R Ar R V G B V N 1 2 V B R R 7 5 A R B Gr V M V G V R R V G V R Gr Gr Ar B Bi R B Ar Bi R G N G N N Bi G N...

Page 102: ...r left direction indicator 17 Right dimmer switch 18 Left dimmer switch 19 Key switch 23 Dashboard 25 Low beam warning light 26 Dashboard lights 27 Fuel level device 29 High beam warning light 30 Dire...

Page 103: ...n relay 18 Voltage regulator 20 Pressure sensor not fitted as standard 22 Rear brake stoplight switch 23 Rear left direction indicator 24 Rear parking brake lamp 26 Oil level switch 31 Left dimmer swi...

Page 104: ...tor 10 Fuel pump 11 H T coil 15 Start relay 16 Starter motor 19 Generator 21 Front brake stoplight switch 25 Rear right direction indicator 27 Control diode 28 Right dimmer switch 29 Key switch 30 Fla...

Page 105: ...ase 00 2003 02 Scarabeo 50 I E 50 100 4T ARRANGEMENT AND FASTENING OF CABLES AND WIRINGS ARRANGEMENT OF CABLES AND WIRINGS 21 40 22 41 29 43 30 32 31 11 5 18 16 33 27 14 26 7 25 23 44 20 2 1 13 15 6 9...

Page 106: ...17 Injection relay 18 Voltage regulator 20 Pressure sensor not fitted as standard 21 Front brake stoplight switch 22 Rear brake stoplight switch 23 Rear left direction indicator 25 Rear right directio...

Page 107: ...106 Release 00 2003 02 Scarabeo 50 I E 50 100 4T FASTENING OF CABLES AND WIRINGS U P Q R S T O L M N F G H I A D E B C...

Page 108: ...107 Release 00 2003 02 Scarabeo 50 I E 50 100 4T...

Page 109: ...108 Release 00 2003 02 Scarabeo 50 I E 50 100 4T NOTES...

Page 110: ...aprilia s p a via G Galilei 1 30033 Noale VE Italy tel 39 041 5829111 fax 39 041 5829190 www serviceaprilia com...

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