3
Release 00
2003-02
Scarabeo 50 I.E.-50/100 4T
PRECAUTIONS AND GENERAL INFORMATION
Follow with care these recommendations when repairing,
disassembling and reassembling the vehicle.
The use of naked flames is forbidden for any type of op-
eration. Before commencing any service or inspection
opera-tion on the vehicle, switch off the engine and re-
move the key, wait until the engine and the exhaust sys-
tem have cooled down and, if possible, raise the vehicle
with the suitable equipment onto firm flat ground.
The brakes also get quite hot in operation. Be sure that
the brakes have cooled thoroughly before beginning any
service operations.
In order to avoid burns, be careful not to touch any parts
of the engine or exhaust systems which have not cooled
down completely.
Avoid the temptation to hold any hardware or other part of
the vehicle in your mouth while working on the
motorscooter.
No part of the motorscooter is edible and some of the coat-
ings, plastics, and platings, etc. are noxious if not out-
right toxic. If not expressly described, the reassembly of
the units is carried out by reversing the order of opera-
tions. Handle fuel with the greatest caution. See gasoline
warning above.
Never use fuel as a solvent for cleaning the vehicle.
Disconnect the negative cable (–) from the battery when
electric welding.
When two or more persons are working together, make
sure that each is working in safe conditions.
Be sure that all the mechanics working on any one vehicle
are thoroughly briefed as what each will be doing, and in-
sure that one mechanic is responsible for insuring that all
safety related items, such as tightening torques, are prop-
erly considered.
BEFORE DISASSEMBLY
– Remove any dirt, mud, dust and foreign matter from the
vehicle before disassembling the components.
– Use, when necessary, the special tools designed for this
vehicle.
Do not use makeshift tools for any operation which calls
for a special tool. Failure to heed this warning can lead to
serious personal injury such as when an ill-fitting wrench
slips, and you slam your hand into the workbench or a
part of the vehicle.
DISASSEMBLING THE COMPONENTS
– Before disconnecting 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 before disassem-
bly.
– Clean and carefully wash all disassembled parts with
fireproof solvent or a nonflammable detergent.
– Keep mating parts together, since they have worn in during
normal use. There are some sets of parts, such as front
sprocket, chain, and rear wheel sprocket, which all must
be replaced as a set.
– Be careful not to put plastic or painted parts close to heat
sources, where they might be damaged.
WARNING
WARNING
REASSEMBLING THE COMPONENTS
Never use a circlip twice. When a circlip is removed,
it must be replaced with a new one.
When assembling a new circlip be careful not to stretch
its ends more than strictly necessary to put it on the
shaft.
After installing a circlip, make sure that it is completely
and firmly inserted in its seat.
Do not use compressed air to clean the bearings.
NOTE
The bearings must rotate freely, without halting
or noise otherwise they must be replaced.
– Use only original
aprilia
SPARE PARTS.
– Use the recommended lubricants.
– Always lubricate parts before reassembly.
– When tightening screws, nuts, and bolts, start with the
largest diameter fasteners. When several fasteners are
arranged in a pattern, start with the innermost fasten-
ers, and tighten diagonally across the pattern.
Tighten each fastener successively before applying the
final tightening torque.
– Always replace gaskets, grommets, circlips, O-rings
and split pins (cotter pins) with new ones.
Before assembling, clean all mating surfaces carefully,
removing all traces of the old gasket and gasket
sealing compound. Also carefully clean any oil seal you
plan to reuse. It is recommended that all oil seals be
replaced each time they are disassembled. Gaskets
should never be reused.
Apply a thin film of lithium based grease to all oil seals
before assembling.
Install oil seals and bearings with the identification
mark or serial number facing outward (visible). Copi-
ously lubricate bearings before installation and be-fore
assembly.
– Make sure that each component has been reassem-
bled correctly.
– After any repair or periodic maintenance operation is
carried out, the vehicle must be test ridden in an area
away from traffic and other hazards.
WARNING