APRILIA SCARABEO 500 - 2008 Service Station Manual Download

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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.

- Lubricate the freewheel «rollers».

Refitting the intermediate gear

- Grease the gear housing on the engine crank-

case.

SCARABEO 500

Engine

ENG - 163

Summary of Contents for SCARABEO 500 - 2008

Page 1: ...SERVICE STATION MANUAL 854190 SCARABEO 500...

Page 2: ...y changes to components parts or accessories which it considers necessary to improve the product or which are required for manufacturing or construction reasons Not all versions shown in this publicat...

Page 3: ...to prevent injuries to the repairer Personal safety Failure to completely observe these instructions will result in serious risk of personal injury Safeguarding the environment Sections marked with t...

Page 4: ......

Page 5: ...TERISTICS CHAR TOOLING TOOL MAINTENANCE MAIN ELECTRICAL SYSTEM ELE SYS ENGINE FROM VEHICLE ENG VE ENGINE ENG INJECTION INJEC SUSPENSIONS SUSP BRAKING SYSTEM BRAK SYS COOLING SYSTEM COOL SYS CHASSIS CH...

Page 6: ...INDEX OF TOPICS CHARACTERISTICS CHAR...

Page 7: ...ep the engine running in order to carry out any procedure please ensure that you do so in an open or very well ventilated area Never let the engine run in an enclosed area If you do work in an enclose...

Page 8: ...F CHILDREN BRAKE FLUID CAUTION THE BRAKE FLUID MAY DAMAGE PAINTED PVC OR RUBBER SURFACES WHEN SERVICING THE BRAKE SYSTEM PROTECT THESE COMPONENTS WITH A CLEAN CLOTH ALWAYS WEAR PROTECTIVE GOGGLES WHEN...

Page 9: ...HE POSSIBLE OVERLAPPING OF OPERATIONS REFERRED TO IN THE OTHER CHAPTERS MUST BE CARRIED OUT LOGICALLY AVOIDING ANY UNNECESSARY RE MOVAL OF COMPONENTS DO NOT POLISH MATT PAINTWORK WITH ABRASIVE PASTES...

Page 10: ...nuts and screws in successive steps before ap plying the tightening torque Always replace self locking nuts washers sealing rings circlips O rings split pins and screws with new ones if their thread...

Page 11: ...DIFFERENT LIQ UIDS WHEN TOPPING UP IN ORDER NOT TO DAMAGE THE BRAKE SYSTEM DO NOT USE BRAKE FLUID TAKEN FROM OLD CONTAINERS OR FROM CONTAINERS THAT HAVE BEEN OPEN FOR A PROLONGED TIME SUDDEN CHANGES I...

Page 12: ...HIGH TEMPERATURE CONTACT WITH SKIN OR CLOTHES MAY CAUSE SEVERE BURNS AND OR INJURIES TYRES CAUTION CHANGING REPAIR MAINTENANCE AND BALANCING ARE IMPORTANT OPERATIONS THAT ARE CARRIED OUT BY QUALIFIED...

Page 13: ...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 Specificatio...

Page 14: ...e Inlet 0 15 mm Outlet 0 15 mm Cooling forced circulation air cooling driven by a centrifu gal pump Lubrication system Forced lubrication with trochoidal pump inside the crankcase oil filter and press...

Page 15: ...55W 2 Front parking light bulb 12V 5W 3 Rear front turn indicator bulb 12V 10W rear 12V 10W front 4 Rear tail light stop light bulb 12V 5W 21W 5 License plate light bulb 12V 5W 6 Instrument panel lig...

Page 16: ...ont tyre pressure passenger rider 2 2 bar Rear tyre pressure passenger rider 2 3 bar Tightening Torques BRAKING SYSTEM UNIT Name Torque in Nm Screw fixing the rear brake pump to the handlebar 10 Screw...

Page 17: ...e silencer clamp to the plate 11 13 Muffler cover fixing screw 12 ENGINE LINK ROD UNIT Name Torque in Nm Pin fixing the connecting rod to the chassis on threaded bushing 10 Nut fixing the connecting r...

Page 18: ...LY Name Torque in Nm Screw fixing the right left rider footrest gusset 10 Nut fixing the coil to the left rider footrest gusset 10 Screw fixing the rear curved support to the chassis 25 Screw fixing r...

Page 19: ...fixing screw 25 Luggage rack central fixing screw 25 Self tapping screw fixing the luggage rack cover 0 6 Self tapping screw fixing the right turn indicator to the tail section 1 Self tapping screw fi...

Page 20: ...ng screw fixing the ornament to the case 1 Washers to key switch cover to shield retainer Screw fixing the right left turn indicator to the cover 1 5 Right stem cover fixing screw TCB 4 2x16 1 Right s...

Page 21: ...rew 3 4 Rpm timing sensor fixing screw 3 4 Screw fixing the valve lifter retaining cover 30 35 inlet manifold fixing screws 11 13 Tappet cover fixing screws 7 9 Throttle body fixing screws 11 13 Camsh...

Page 22: ...over screws 7 9 Flywheel cover screws 11 13 FLYWHEEL COVER Name Torque in Nm Flywheel fixing nut 115 125 Stator clamps 8 10 Blow by scavenge duct fixing screws 3 4 Screws fixing freewheel to flywheel...

Page 23: ...der Piston Play on fitting Cylinder Piston A 93 990 93 997 93 954 93 961 0 029 0 043 Cylinder Piston B 93 997 93 004 93 961 93 968 0 029 0 043 Cylinder Piston C 94 004 94 011 93 968 93 975 0 029 0 043...

Page 24: ...0 50 mm Max value 0 65 mm Oil scraper ring 0 25 0 50 mm Max value 0 65 mm Rings slots coupling clearances Carefully clean the sealing ring housings Check coupling clearances by placing a thickness ga...

Page 25: ...Crankcase crankshaft connecting rod Crankshaft bearing diameter Measure the bearings on both axes X Y CRANKSHAFT Specification Desc Quantity Cat 1 Standard diameter 40 010 40 016 Cat 2 Standard diamet...

Page 26: ...houlder 1 0 025 A D 0 20 0 50 Half shaft trans mission side 20 9 0 05 B D 0 20 0 50 Connecting rod 22 0 10 0 15 C D 0 20 0 50 Flywheel side shoulder 1 8 0 025 F D 0 20 0 50 Half shaft flywheel side 19...

Page 27: ...ft half bearings arranging the crankshaft so as to match the specified couplings The crankcase halves can be equipped with four types of crankshaft half bearings identified by letters A red B blue C y...

Page 28: ...PRO TRUDES BEYOND THE PLANE FORMED BY THE CYLINDER UPPER END THE THICKER THE GASKET TO BE USED AT THE CYLINDER BASE B SHOULD BE ON THE OTHER HAND THE MORE THE PISTON CROWN IS RE CESSED INTO THE CYLIN...

Page 29: ...oil AGIP FORK 7 5W Fork oil AGIP GREASE SM2 Lithium grease with molybdenum for bearings and other points needing lubrication NLGI 2 AGIP BRAKE 4 Brake fluid FMVSS DOT 4 Synthetic fluid AGIP PERMANENT...

Page 30: ...INDEX OF TOPICS TOOLING TOOL...

Page 31: ...er for bearing with OD 73 mm 001467Y006 Pliers to extract 20 mm bearings 001467Y007 Driver for bearings with OD 54 mm 001467Y008 Pliers to extract 17 mm bear ings 001467Y014 Pliers to extract 15 mm be...

Page 32: ...bear ings 001467Y035 Driver for bearings with OD 47 mm 020074Y Supporting base for checking crankshaft alignment 020151Y Air heater 020150Y Air heater support AP8140181 Fuel pressure check tool 02026...

Page 33: ...tion 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 SCARABEO 5...

Page 34: ...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 Tooling SCARABEO 500 T...

Page 35: ...75Y 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 S...

Page 36: ...riven 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 24 mm adaptor AP8140595 Axone battery...

Page 37: ...P8202311 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 SCAR...

Page 38: ...iption 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 Tooling SCA...

Page 39: ...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 SCARA...

Page 40: ...s code Description AP8106702 Flywheel lock calliper spanner AP8140187 Engine supporting stand 020648Y Single battery charger 020661Y Water pump overall sealing re placement kit Tooling SCARABEO 500 TO...

Page 41: ...INDEX OF TOPICS MAINTENANCE MAIN...

Page 42: ...55 000 KM 65 000 KM 10 Action Engine oil level check topping up Brake pads condition and wear check Centre stand lubrication AFTER 10 000 KM 50 000 KM 70 000 KM 120 Action Safety locks check Driving b...

Page 43: ...cks variable speed rollers replacement Tyre pressure and wear check Vehicle and brake test test drive Hub oil change Suspensions check Steering check Centre stand lubrication Brake fluid level check 3...

Page 44: ...ollows Lift the saddle Remove the battery cover Undo and remove the two screws 1 fixing the central inspec tion cover Lower the saddle Undo and remove the lower central fixing screw 2 Slide off the ce...

Page 45: ...ine Re place the spark plug if there are cracks on its insulating material corroded electrodes or large deposits Check electrode gap with a thickness gauge and adjust if necessary by care fully bendin...

Page 46: ...n firm and level ground Rest the vehicle on its centre stand Unscrew and take out the measuring cap dipstick 1 Clean the area in contact with oil with a clean cloth Screw the cap dipstick 1 fully down...

Page 47: ...G THE VEHICLE WITH INSUFFICIENT LUBRICATION OR CONTAMINATED OR NOT REC OMMENDED LUBRICANTS ACCELERATES THE WEAR AND TEAR OF MOVING PARTS AND CAN CAUSE IRRETRIEVABLE DAMAGE Replacement Park the vehicle...

Page 48: ...API GL4 GL5 Characteristic Transmission oil 250 cm 15 3 cu in Air filter Remove the filtering element from the vehicle for cleaning Removal Rest the vehicle on its centre stand Undo and remove the nin...

Page 49: ...iving at full speed all the time oil consumption increases CAUTION OPERATING THE SCOOTER WITH INSUFFICIENT OIL CAN DAMAGE THE ENGINE Replacement CAUTION PARK THE VEHICLE ON SAFE AND LEVEL GROUND Rest...

Page 50: ...ended transmission oil through the fill opening Recommended products AGIP CITY HI TEC 4T Engine oil API SL ACEA A3 JASO MA Characteristic Engine oil 1700 cm 103 74 cu in Screw and tighten the measurin...

Page 51: ...SULT IN AN INCORRECT READING OF THE ENGINE OIL LEVEL Unscrew and pull out the measuring cap dipstick 1 Clean the area in contact with oil with a clean cloth Screw the cap dipstick 1 fully down into it...

Page 52: ...d tighten the cap dipstick 1 CAUTION RIDING THE VEHICLE WITH INSUFFICIENT LUBRICATION OR CONTAMINATED OR NOT REC OMMENDED LUBRICANTS ACCELERATES THE WEAR AND TEAR OF MOVING PARTS AND CAN CAUSE IRRETRI...

Page 53: ...nto contact with the gasket and further tighten to the prescribed torque Fill with recommended engine oil refer to the Recommended Products table and to pre scribed amount refer to Engine oil change s...

Page 54: ...AX reference marks MIN minimum level MAX maximum level Top up if necessary Top up CAUTION WAIT FOR THE ENGINE TO COOL DOWN BEFORE CHECKING OR TOPPING UP COOLANT LEVEL Loosen but do not remove the fill...

Page 55: ...system CAUTION CONSIDERING THE DANGER FOR VEHICLE AND RIDER IT IS STRICTLY NECESSARY AFTER REFITTING BRAKES AND RESTORING THE BRAKING SYSTEM TO THE REGULAR USE CON DITIONS THAT THE HYDRAULIC CIRCUIT B...

Page 56: ...mum level CAUTION DO NOT USE YOUR VEHICLE IF THE FLUID DOES NOT REACH AT LEAST AT THE MIN REFERENCE MARK If the fluid does not reach at least the MIN reference mark Check the brake pads and discs for...

Page 57: ...INLY WHEN THE BRAKE FLUID RESERVOIR COVER HAS BEEN REMOVED PLACE A CLOTH UNDER THE BRAKE FLUID RESERVOIR TO PROTECT IT FROM ANY FLU ID SPLASHES CAUTION TOP UP TO MAXIMUM LEVEL MARK ONLY WHEN BRAKE PAD...

Page 58: ...he vehicle on its centre stand Visually check the brake disc and pads as indicated below Front brake callipers From the front bottom side for both pads Repeat the operation for the other calliper Rear...

Page 59: ...ASHES FOR ABOUT 5 SECONDS AFTER THE IGNITION CHECK 300 KM 186 mi TO THE NEXT SERV ICE ONCE THE MILEAGE FOR A SERVICE HAS BEEN REACHED THE ICON WILL BE STEADILY ON UNTIL THE SERVICE IS CAR RIED OUT Sev...

Page 60: ...ion NOTE THE DISPLAYED FUNCTION IS RESET DIGITAL ODOMETER These are the segments of the digital odometer functions on the LCD display Trip odometer icon 5 6 digit display 2 Unit of measurement in km i...

Page 61: ...justment mode If no button is pressed within three seconds the display automatically exits the clock adjustment function and goes back to the function it displayed before the clock adjustment mode was...

Page 62: ...irection of the front light beams place the vehicle ten metres from a vertical wall and make sure the ground is level Turn on the low beam light sit on the vehicle and check that the light beam projec...

Page 63: ...INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS...

Page 64: ...Components arrangement Electrical system SCARABEO 500 ELE SYS 64...

Page 65: ...on the component 2 MAIN FUSES Location under the specific battery cover placed in the helmet compartment 3 AUXILIARY FUSES Location under the specific battery cover placed in the helmet compartment 4...

Page 66: ...6 INSTRUMENT PANEL DIAGNOSTICS SOCK ET Location under the battery cover placed in the helmet compartment 7 INSTRUMENT PANEL Connector location on the component 8 PLUG SOCKET Location inside the front...

Page 67: ...k plate to reach it Connector location under the central cover near the fuel level sensor 11 OIL SENSOR Location on the engine on the vehicle right fairing Connector location on the component 12 START...

Page 68: ...nt part of the vehicle near the component supporting plate Remove the leg shield to reach it Connector location on the component 16 RELAY Location at the front part of the vehicle on the component sup...

Page 69: ...OL UNIT Location at the front part of the vehicle near the key switch Remove the legshield to reach it Connector location on the component 19 KEY SWITCH Location at the front part of the vehicle Remov...

Page 70: ...tail section to reach it Connector location on the component 23 SPARK PLUGS Location at the front part of the engine Remove the central inspection cover to reach them 24 SIDE STAND SWITCH Location at...

Page 71: ...n on the fuel tank Remove the central cover to reach it Connector location on the component Ground points Ground point on the engine Placed on the vehicle right side next to the swing ing arm support...

Page 72: ...AIN CABLE HARNESS FITTING KEY 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 290x4 5 Clam...

Page 73: ...KEY 1 Do not use any clamps 2 290x4 5 Clamp SCARABEO 500 Electrical system ELE SYS 73...

Page 74: ...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 Electrical system SCARABEO 500 ELE SYS...

Page 75: ...KEY 1 98x2 5 Clamp 2 290x4 5 Clamp KEY 1 290x4 5 Clamp holds the Main Cable Harness and Flywheel cables SCARABEO 500 Electrical system ELE SYS 75...

Page 76: ...2 180x4 5 Clamp 3 290x4 5 Clamp do not pull with force KEY 1 Cable guide plus a clamp 2 290x4 5 Clamp Electrical system SCARABEO 500 ELE SYS 76...

Page 77: ...KEY 1 Cable guide plus a clamp 2 98x2 5 Clamp SCARABEO 500 Electrical system ELE SYS 77...

Page 78: ...KEY 1 98x2 5 Clamp 2 98x2 5 Clamp 3 98x2 5 Clamp KEY Electrical system SCARABEO 500 ELE SYS 78...

Page 79: ...t up relay fitted on the rubber ring 2 Cable guide plus a clamp 3 98x2 5 Clamp KEY 1 180x4 5 Clamp 2 180x4 5 Clamp 3 98x2 5 Clamp 4 98x2 5 Clamp RIGHT LIGHT SWITCH SCARABEO 500 Electrical system ELE S...

Page 80: ...KEY 1 98x2 5 Clamp LEFT LIGHT SWITCH KEY 1 98x2 5 Clamp Electrical system SCARABEO 500 ELE SYS 80...

Page 81: ...SPEED SENSOR FITTING KEY 1 98x2 5 Clamp 2 98x2 5 Clamp 3 98x2 5 Clamp SCARABEO 500 Electrical system ELE SYS 81...

Page 82: ...KEY 1 Speed Sensor Connection 2 98x2 5 Clamp Back side MAIN CABLE HARNESS FITTING Electrical system SCARABEO 500 ELE SYS 82...

Page 83: ...EY 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 SCARABEO 500 Electrical system ELE SYS 8...

Page 84: ...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 Electrical system SCARABEO 500 ELE SYS 84...

Page 85: ...EY 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 SCARABEO 500 Electrical system ELE SYS 85...

Page 86: ...KEY 1 180 x 4 5 Clamp KEY 1 Glove box Light Connector 2 180 x 4 5 Clamp Electrical system SCARABEO 500 ELE SYS 86...

Page 87: ...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 SCARABEO 500 Electrical system ELE SYS 87...

Page 88: ...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 Electrical system SCARABEO 500 ELE SYS 88...

Page 89: ...KEY 1 Cable harness installation inside the Battery Compartment KEY 1 Cable harness installation inside the Battery Compartment SCARABEO 500 Electrical system ELE SYS 89...

Page 90: ...ssure 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 Electrical system SCARAB...

Page 91: ...KEY 1 98 x 2 5 Clamp 2 LAMBDA probe 3 290 x 4 5 Clamp CHASSIS ENGINE GROUND LEAD FITTING SCARABEO 500 Electrical system ELE SYS 91...

Page 92: ...KEY 1 Screw 2 Screw START UP RELAY STARTER MOTOR CABLE FITTING KEY 1 290 x 4 5 Clamp Electrical system SCARABEO 500 ELE SYS 92...

Page 93: ...KEY 1 290 x 4 5 Clamp 2 Cable guide LICENSE PLATE LIGHT CABLE HARNESS FITTING KEY SCARABEO 500 Electrical system ELE SYS 93...

Page 94: ...his in its turn is connected directly to the ground lead and the battery positive terminal passing through the 30A protective fuse This system requires therefore no connection to the key switch The th...

Page 95: ...positives in the regulator output Keep lights on start the engine take it to a high running speed and at the same time read the values on the ammeter With an efficient battery the following value must...

Page 96: ...indicator switch Check the turn indicator switch contacts Check if with the turn indicator switch pressed to the left there is voltage between terminal 16 Light blue cable of the instrument panel and...

Page 97: ...EPLACE A FUSE WITH ANY OTHER MATERIAL A PIECE OF ELEC TRIC WIRE OR A FUSE WITH A HIGHER AM PERAGE THAN REQUIRED MAIN FUSES Specification Desc Quantity 1 Fuse No 2 Capacity 30A Protected circuits batte...

Page 98: ...ith the Service mileage During the 300 km 200 mi before the service warning light comes on the light flashes 5 times each time the key is set to ON The light should turn on first at 1000 km 625 mi Suc...

Page 99: ...N WASH ABUNDANTLY WITH WATER FOR APPROX 15 MIN AND SEEK IMMEDIATE MEDICAL ATTENTION IN ACCIDENTALLY SWALLOWED IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR MILK FOLLOWED BY MAGNESIUM MILK BATTERED EG...

Page 100: ...ht of 1 26 1 28 must be at a minimum temperature of 15 C A density reading below 20 B indicates that the battery is completely flat and must therefore be recharged If the vehicle is not used for a cer...

Page 101: ...PACITY HIGHER THAN THE RECOMMENDED CAPACITY USING A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE A FIRE CAUTION ORDINARY DRINKING WATER CONTAINS MINERAL SALTS THAT ARE HARM...

Page 102: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE...

Page 103: ...ani 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 Undo and remove the exhaust end fix ing screw Remove the e...

Page 104: ...the manifold with the gasket Removal of the engine from the vehicle Rest the vehicle on its centre stand Remove the tail section Remove the helmet compartment Loosen the clamp NOTE USE A CONTAINER OF...

Page 105: ...ove the two side screws fixing the rear mudguard collect the two shim washers Working on the left side of the vehicle undo and remove the two side screws fixing the rear mudguard collect the two washe...

Page 106: ...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 Engine from vehicle SCA...

Page 107: ...ve 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 SCARABEO 500 E...

Page 108: ...bsorber 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 Engine from vehicle SCARA...

Page 109: ...OTE 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 Slide off the fuel pipe Undo and remove the...

Page 110: ...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 Undo and remove the screw fixing th...

Page 111: ...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 Remove t...

Page 112: ...the screw fixing the exhaust end sealing clamp Push in the exhaust and remove the upper pin fixing the sealing clamp Undo and remove the exhaust end fix ing screw Remove the exhaust end Remove the sa...

Page 113: ...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 SCARABEO 500...

Page 114: ...he wheel Remove the wheel NOTE PLACE AN ADEQUATE SUPPORT AT THE LOWER PART OF THE MOTOR VEHICLE Undo and remove the screw fixing the rear brake pipe and collect the spacer Undo and remove both screws...

Page 115: ...fixing nut Release the positive lead Working on the right side unscrew the nut fixing the swinging arm pin and col lect the washer Unscrew and remove the link rod fixing nut and collect the washer an...

Page 116: ...he tightening torques shown in the Specifications Chapter Check the engine oil level and if necessary top up with the recommended type of oil Fill and bleed the cooling circuit Check the throttle grip...

Page 117: ...INDEX OF TOPICS ENGINE ENG...

Page 118: ...riven pulley axis cover by acting on the bottom of the cap Loosen the nut fixing the driven pulley shaft using an offset wrench and prevent pulley shaft rotation using an industrial type hexagonal soc...

Page 119: ...ise replace it Air duct Remove the transmission cover To remove the air deflector undo the two screws indicated in the figure Locking torques N m Air deflector screws 11 12 Remove the external transmi...

Page 120: ...d use the specific tool so that it is ade quately supported Extract the bearing with the specific tool NOTE BELL MUST BE PLACED INTO THE TRANS MISSION COVER CLOSE TO THE BEARING SEAT AND THE WOODEN SU...

Page 121: ...D SURFACE Specific tooling 020376Y Adaptor handle 020358Y 37 x 40 mm adaptor 020439Y 17 mm guide Baffle roller Plastic roller Check that the roller shows no signs of abnormal wear and that it rotates...

Page 122: ...ecting the clutch drum Make sure that the clutch bell is not worn or dam aged Measure the clutch bell inside diameter NOTE CHECK THE ECCENTRICITY FOUND IT SHOULD BE 0 2 MM MAX Characteristic Max value...

Page 123: ...n the inside Fit the adaptor ring on the clutch assembly as indicated in the photograph Fit the driven pulley unit on the tool by inserting the pins in the ventilation holes Push the rear stop screw u...

Page 124: ...signs of wear or damage on the bushing otherwise replace the fixed driven half pulley Remove the snap ring with pliers With the specific tool inserted through the roller bearing pull out the ball bea...

Page 125: ...m Inspecting the driven fixed half pulley Check that the belt faying surface does not show signs of wear Measure the outside diameter of the pulley bush ing Characteristic Minimum diameter allowed 49...

Page 126: ...use the specific tool Specific tooling 020478Y Punch for roller casing 001467Y002 Driver for bearing with OD 73 mm Fit a new ball bearing with the specific tool Specific tooling 020376Y Adaptor handle...

Page 127: ...C ring of the tone wheel Soap based lithium grease containing NLGI 2 Molybdenum disulphide 2 ISO L XBCHB2 DIN KF2K 20 Inspecting the clutch spring Measure the length of the movable driven half pulley...

Page 128: ...ch on the driven pulley Locking torques N m Clutch ring nut 65 75 To facilitate refitting the clutch on the engine turn the movable driven pulley and insert the belt into the smaller diameter Refittin...

Page 129: ...ng nuts Unscrew the central nut Remove both the belleville and the plain washer Remove the fixed driving half pulley Remove the connecting washer with the bushing Move the belt downwards Suitably supp...

Page 130: ...29 959 mm Check that the rollers are not damaged or worn Characteristic Minimum diameter allowed 24 5 mm Standard diameter 24 9 mm Check the guide shoes for the variator roller con trast plate are not...

Page 131: ...itting 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 Assembly the half pulley with the roller contrast...

Page 132: ...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 Fit the nut in the previous workin...

Page 133: ...nally fit the tool by manually drawing the nuts close and making sure that the tool lays horizon tally Tighten the driving pulley fixing nut to the pre scribed torque Remove the specific tool Locking...

Page 134: ...ghten the driven pulley shaft fixing nut using an offset wrench NOTE DUE TO THE HIGH TIGHTENING TORQUE US ING DIFFERENT WRENCHES TRADITIONAL MULTI POINT SOCKET WRENCH MAY DAM AGE THE HEXAGON LOCATED O...

Page 135: ...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 Remove the 7 fixing screws Remove the hub cover and the rel...

Page 136: ...to extract 15 mm bear ings 001467Y031 Driver Use the appropriate extractor to remove the bear ing on the engine crankcase of the transmission shaft Specific tooling 001467Y006 Pliers to extract 20 mm...

Page 137: ...r 020483Y 30 mm guide Remove the oil seal using a screwdriver Removing the driven pulley shaft bearing Should the driven pulley shaft its bearing and oil seal be removed take out the transmission cove...

Page 138: ...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 If faults are found replace the dam...

Page 139: ...the hub cover Refitting the driven pulley shaft bearing Heat the crankcase with an air heater Specific tooling 020151Y Air heater 020150Y Air heater support Using the specific tool fit the driven pul...

Page 140: ...of the wheel axle bearing on the crankcase Fit the wheel axle bearing in the upper crankcase seat using the specific tool NOTE PLACE IT WITH THE BALLS FACING THE HUB SIDE THIS APPLIES TO BEARINGS WITH...

Page 141: ...e 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 Specif...

Page 142: ...cover bearings Heat the bearing seats on the cover using the air heater Support the hub cover using the stud bolt set Specific tooling 020151Y Air heater 020150Y Air heater support Fit the intermediat...

Page 143: ...0Y 52 x 55 mm adaptor 020483Y 30 mm guide Refit the circlip Support the hub cover using the stud bolt set Fit the wheel axle oil seal with the sealing lip fac ing the inside of the cover Place the oil...

Page 144: ...ver NOTE THE CLAMPS MUST BE REPLACED TO RE MOVE THEM OPEN OR CUT THEM USING A SCREWDRIVER BE CAREFUL NOT TO DAMAGE THE PLASTIC UNIONS Removing the hub cover Drain the engine oil by removing the draina...

Page 145: ...OTE THEIR POSITIONS CAUTION REMOVE THE COVER AVOIDING ANY POSSIBLE INTERFERENCE BETWEEN STATOR AND ROTOR CAUTION BE CAREFUL NOT TO DROP THE BY PASS VALVE AND THE RELEVANT SPRING Removing the flywheel...

Page 146: ...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 Remove the blow...

Page 147: ...torque limiter bearing and the water pump shaft bearing are not worn Characteristic By pass housing hole diameter 13 9 mm Bearing diameter for start up gear shaft 12 mm Bearing diameter for pump shaft...

Page 148: ...cable thoroughly as it consists of two types of cables rigid cables close to the stator and flexible cables close to the con nector Check that the winding is placed so as not to in terfere with the h...

Page 149: ...ss guide bracket screws 3 4 Refitting the flywheel cover components Before refitting check that all components are perfectly clean For the cover housing carefully check all lubri cation channels espec...

Page 150: ...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...

Page 151: ...ery 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 NOTE LUB...

Page 152: ...er 12 16 Fit the feed coupling to the cylinder and connect the return coupling to the pump cover using 3 new clamps NOTE TIGHTEN THE CLAMPS USING APPROPRIATE PLIERS PAY ATTENTION NOT TO MARK COU PLING...

Page 153: ...e crankshaft in order to align the counter shaft drive with a reference mark on the crankcase see figure Repeat the alignment for the water pump shaft using the same reference mark on the cover NOTE T...

Page 154: ...ree 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...

Page 155: ...enough to measure the rpm and starter motor input NOTE THE DECLARED RPM VALUE IS THAT INDICATED BY THE DIAGNOSTIC TESTER THE RPM READING IS NOT THE REAL ONE BUT IT IS VALID FOR DIAGNOSIS PURPOSES Spe...

Page 156: ...ws 10 The motor works properly 11 Check the armature rotation 12 Finally replace the start up remote control switch 13 Check the battery again and if necessary replace the starter motor NOTE IF THE CR...

Page 157: ...ven dangerous conditions The start up control circuit is not controlled by the immobiliser system therefore before insisting on the starter system in an abnormal way check the immobiliser enabling swi...

Page 158: ...xtractor 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 fully to the end and almost flu...

Page 159: ...ED IF THE CONE GETS DETACHED THIS MAY CAUSE THE RO TOR TO FALL AND CONSEQUENTLY THE MAGNETS MAY BREAK Fit the specific extractor Using a 27 mm wrench and a 19 mm bushing release the flywheel Specific...

Page 160: ...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 The freewheel is coupled to the flywheel with high precision i...

Page 161: ...665 mm 0 008 0 005 mm 1 79 in 0 0003 0 0002 in Check the inside diameter of the start up gear bushing Check that the toothing is not worn Characteristic Bushing inside diameter 27 mm 0 020 0 041 mm 1...

Page 162: ...Driven plates consist of 4 Belleville springs with grooved profiles this assembly allows transmitting torques lower than 10 kgm In case of incorrect start up procedures the torque limiter prevents any...

Page 163: ...t 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 Lubricate the freewhee...

Page 164: ...starting ring gear on the flywheel by turning it clockwise and inserting the gear at the same time Refitting the flywheel magneto Insert the key on the crankshaft Fit the magneto flywheel checking th...

Page 165: ...URE TO OBSERVE THIS RULE CAUSES THE GUIDE ON THE FLYWHEEL TO GET LOCKED Specific tooling 020472Y Flywheel lock wrench Align the 2 holes of the magneto flywheel with the seat on the crankcase to fit th...

Page 166: ...MAKES CONTACT WITH THE CRANKCASE AND CHECK THAT IT IS FREE TO ROTATE ANTI CLOCKWISE Locking torques N m Chain guide slider plate fixing screws 3 4 Refitting the starter motor Check that the O ring is...

Page 167: ...ving 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 Remove the...

Page 168: ...ific tool Specific tooling AP8106702 Flywheel lock calliper spanner Remove the return spring and the valve lifter mass with relevant end of stroke washer NOTE BE CAREFUL SO THAT THE SPRING AND THE WAS...

Page 169: ...r weight as shown in the figure Remove the timing chain gear from the camshaft Remove the gear from the timing chain Removing the cam shaft Remove the 3 fixing screws and the camshaft re taining brack...

Page 170: ...pins and the rocking levers acting from the transmission side holes Removing the cylinder head Remove the spark plugs Remove the cooling system outlet sleeve togeth er with the thermostat Remove the c...

Page 171: ...OGETHER WITH THE CAMSHAFT ROCKING LEVER PINS AND MOUNTING BRACKET Loosen the 4 head cylinder fixing nuts in two or three stages and in a criss crossed sequence Remove the head the 2 centring dowels th...

Page 172: ...essor adaptor CAUTION ARRANGE THE VALVES SO AS TO RECOGNISE THEIR ORIGINAL POSITION ON THE HEAD FLYWHEEL SIDE AND TRANSMISSION SIDE Remove the oil seals with the specific tool Specific tooling 020431Y...

Page 173: ...TO AVOID DAMAGING THE PISTON KEEP IT FIRM WHILE REMOVING THE CYLINDER Remove the 2 piston pin snap rings operating through the specific slots Slide off the pin and remove the piston NOTE USE PAPER OR...

Page 174: ...Characteristic Standard diameter 22 0 025 0 015 mm Inspecting the wrist pin Check the pin outside diameter using a micrometer Characteristic Standard diameter 22 0 004 mm Calculate the rod small end...

Page 175: ...PISTON AND THE CYLIN DER PISTON COUPLING CLEARANCE REFER TO THE SPECIFICATIONS SECTION Characteristic A 10 mm Piston diameter Nominal value 94 mm Using a bore meter measure the cylinder inside diamete...

Page 176: ...he opening of the sealing rings using a thickness gauge see picture Replace the piston rings if values higher than those prescribed are measured Check the size of the sealing ring opening Compression...

Page 177: ...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 Fit the pin snap ring in the specific tool with the open...

Page 178: ...sting surface reset the dial gauge with a preloading of a few millimetres Finally fix the dial gauge Check the perfect sliding of the feeler pin Fit the tool on the cylinder without changing the dial...

Page 179: ...o the spring union and the word top facing the piston crown In any case the chamfered side of the must be facing the piston crown Fit the middle piston ring with the identification letter or the word...

Page 180: ...68Y Piston fitting ring 020512Y Piston fitting fork Inspecting the cylinder head Using a trued bar and a thickness gauge check that the cylinder head surface is not worn or distorted Characteristic Ma...

Page 181: ...NION REPLACE THE CRANKSHAFT AS DESCRIBED IN THE CRANKCASE AND CRANKSHAFT CHAPTER Chain tensioner Remove the central screw with the washer and the tensioner spring Check that the one way mechanism is n...

Page 182: ...V with Prussian blue Characteristic Standard value 1 1 3 mm Limit allowed 1 6 mm If the width of the mark on the valve seat is larger than the prescribed limits true the seats with a 45 milling cutte...

Page 183: ...l gauge at a right angle with respect to the valve head and rotating it on the V shaped support Characteristic Limit allowed 0 03 mm Inspecting the valve stem guide clearance After measuring the valve...

Page 184: ...s Grind the valves gently with fine grained lapping compound Upon grinding keep the cylin der head in horizontal position This will prevent the lapping compound residues from penetrating between the v...

Page 185: ...e 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 Specific tooling 020306Y Punch for fitting valve se...

Page 186: ...rings and insert the cotters in their seats Specific tooling 020382Y Tool for removing valve cotters fitted with part 012 020382Y012 bushing valve removing tool NOTE DO NOT CHANGE THE VALVE FITTING PO...

Page 187: ...nlet 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 re...

Page 188: ...0 0 018 mm Check the inside diameter of each rocking lever Characteristic Standard diameter 13 0 026 0 015 mm Check there are no signs of wear on the contact pads with the cam and on the articulated p...

Page 189: ...stud bolts in a criss crossed sequence to the prescribed torque as shown in the figure Locking torques N m Head fixing stud bolts First apply a preliminary torque of 7 Nm in a criss crossed sequence...

Page 190: ...the prescribed torque Locking torques N m Spark plug 12 14 Nm Fit the timing control chain on the crankshaft ob serving the initial direction of rotation Fit the tensioner pad with the relevant spacer...

Page 191: ...d products Loctite 243 Medium strength threadlock Insert the camshaft retaining bracket so that the countersinks are visible and tighten the 3 fixing screws to the prescribed torque being careful not...

Page 192: ...the reference on the magnet support is aligned with that on the fly wheel cover Install the counterweight mass Centre using the cover fixing screw Lock the mass fixing screws to the prescribed torque...

Page 193: ...ten the fixing screw to the prescribed torque using the recommended product NOTE BELL TIMING IS ENSURED BY THE BALANCE WEIGHT MASS FIXING SCREW HEAD Recommended products Loctite 243 Medium strength th...

Page 194: ...the spring with the central screw and the washer Tighten the central screw to the prescribed tor que Locking torques N m Tensioner screw 5 6 Place the engine with the valve clearance adjustment timin...

Page 195: ...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 strob...

Page 196: ...ct 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 test...

Page 197: ...the remaining 4 screws in a criss crossed sequence 3 4 5 6 NOTE PAY ATTENTION TO THE CORRECT POSITION OF THE GASKET Locking torques N m Tappet cover fixing screws 7 9 Fit the driving pulley with the...

Page 198: ...hermal group cylinder head piston as described in the Thermal group and Timing system chapter Before opening the engine crankcase it is advisable to check the axial clearance of the crankshaft For thi...

Page 199: ...ft For this purpose use a plate e g the specific tool and a support with specific tool dial gauge Specific tooling 020262Y Crankcase splitting strip 020335Y Dial gauge magnetic support Characteristic...

Page 200: ...ft Before removing the crankshaft check the timing with the countershaft To carry out this check turn the crankshaft until the two holes on the crankshaft and the hole on the countershaft control gear...

Page 201: ...LOC TITE BE CAREFUL NOT TO DAMAGE THE CONTROL HEXAGON FOR BETTER RESULTS IT IS PREFERABLE TO USE AN INSIDE HEXA GON BOX SPANNER Removing the countershaft Place the specific tool as shown in the figure...

Page 202: ...let Specific tooling 020376Y Adaptor handle 020358Y 37 x 40 mm adaptor 020439Y 17 mm guide Remove the bearing from the transmission side crankcase half using the specific tool Specific tooling 001467Y...

Page 203: ...9Y 17 mm guide Fit the Seeger ring Before fitting the new bearing on the transmis sion side crankcase heat the seat using the spe cific tool Specific tooling 020151Y Air heater 020150Y Air heater supp...

Page 204: ...e are not scored and with the aid of a gauge measure the crankshaft width as shown in the fig ure NOTE BE CAREFUL NOT TO LET THE MEASURE MENT BE AFFECTED BY THE UNIONS WITH THE CRANKSHAFT BEARINGS Cha...

Page 205: ...both crankshaft bearings according to the axes and surfaces shown in the figure Half shafts are classified in two categories Cat 1 and Cat 2 as shown in the chart below STANDARD DIAMETER Specification...

Page 206: ...e NOTE SHOULD A CRANKSHAFT CONSISTING OF TWO HALF SHAFTS OF DIFFERENT CATEGORIES NEED REPLACING REPLACE BOTH CRANKCASE HALVES AS WELL COUPLING THE TWO COMPONENTS SHAFT AND CRANKCASE WITH THE SAME CATE...

Page 207: ...EALING OF THE LUBRICATION PRESSURE ADJUSTMENT PISTON THE HEAD LUBRICATION CHANNEL IS FITTED WITH A SHUTTER JET THIS GIVES A LOW PRESSURE HEAD LUBRICATION THIS CHOICE HAS BEEN MADE TO REDUCE THE OIL TE...

Page 208: ...ompared with the crankshaft axial clearance of the limiting surface NOTE TO KEEP THIS POSITION OF THE BUSHINGS ON THE CRANKCASE FITTING IS FORCED ON CAST IRON RINGS INSERTED IN THE CASTING OF CRANKCAS...

Page 209: ...shaft category Y Crankcase half shells category A Red B Blue C Yellow D Green In case of breakdown crankcases come together with bushings and are classified according to the axial distance of the coun...

Page 210: ...BE ABOVE REMOVE THE COMPLETE DRIVEN PULLEY AND THE ANTI FLAPPING ROLLER FROM THE TRANSMISSION SIDE CRANKCASE HALF AS DESCRIBED IN THE AUTOMATIC TRANS MISSION CHAPTER AND THE HUB COVER WITH THE RELEVAN...

Page 211: ...re for the 4 fixing screws Insert the control gear on the crankshaft with the bore countersink visible Tighten the 4 fixing screws to the prescribed torque NOTE TO AVOID DAMAGING THE SCREW CONTROL HEX...

Page 212: ...HED PINION Install the oil pump housing cover Tighten the 2 flanged fixing screws to the pre scribed torque Locking torques N m Oil pump compartment cover bulkhead screws 8 10 Refitting the crankcase...

Page 213: ...ed torque Check the crankshaft rotation NOTE REMOVE ANY RESIDUES FROM THE CRANKCASE COUPLING GASKET ON THE CYLINDER SURFACE TO ENSURE BETTER SEALING Locking torques N m Engine crankcase coupling screw...

Page 214: ...0 0 0047 in Flatness 0 015 mm 0 00059 in BY PASS Specification Desc Quantity Type with piston Piston diameter 13 984 13 957 mm 0 5505 0 5495 in Unloaded spring length 52 mm 2 05 in Calibration pressur...

Page 215: ...ty A Camshaft B Cylinder head plane C Cylinder crankcase plane D Water pump rotor E Minimum oil pressure sensor F Oil filter cartridge G To the oil sump H By pass valve L Oil pump M Oil mesh pre filte...

Page 216: ...side bearing the supply to the head is controlled by the specific spray jet in the engine crankcase The components of the timing system work with low pressure oil The camshaft bearings are marked dir...

Page 217: ...ure check Remove the dipstick with the oil filler plug and insert a plug with the temperature probe supplied with the specific tool Insert the probe to feel contact with the crankcase bottom and pull...

Page 218: ...he Crankcase and Crankshaft chapter radial clearance especially in the direction of the cylinder axis clearance according to the direction of rotation with the connecting rod in quadrature YES go to p...

Page 219: ...HE PRESCRIBED VISCOSITY A HIGHER VISCOSITY CAUSES AN INCREASE OF THE SYSTEM PRESSURE 1 If oil consumption is higher than 250 gr 1000 km on run in engine proceed as follows CONTINUE go to point 2 2 Che...

Page 220: ...oing 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 po...

Page 221: ...the shaft with the gear and install the lock ring afterwards turn it with the opening opposed to the shaft face Check any irregular clearance between shaft and pump body Measure distance between rotor...

Page 222: ...pump cover If you detect non conforming values or scoring replace the faulty parts Fit the pump cover so positioned that the holes for the crankcase fixing screws are aligned Tighten the two fixing s...

Page 223: ...he position shown in the figure Specific tooling 020479Y Countershaft lock wrench Keep the countershaft in position and insert the washer with the nut Tighten the nut to the prescribed torque using th...

Page 224: ...ankcase edge and disassemble the overall seal ing pressure fitted on the rotor shaft CAUTION USE TEFLON AS SHOWN IN THE FIGURE SO AS NOT TO DAMAGE THE WATER PUMP COV ER SEALING SURFACE SMALL SCRATCHES...

Page 225: ...tatic part of the seal using the pin supplied and a hammer NOTE MAKE THE HOLES WITH A STRONG HIT MULTIPLE BLOWS COULD DEFORM THE PART WITHOUT PASSING THROUGH Fasten the extractor to the static part of...

Page 226: ...extractor with the static part of the overall sealing montaggio OVERALL SEALING FITTING CAUTION CLEAN ALL THE COMPONENTS CAREFULLY CAUTION LUBRICATE THE ROTOR SHAFT WITH OIL Fit the tie rod screwing i...

Page 227: ...the shaft producing the correct ceramic seal preloading Screw the rotor Locking torques N m Water pump rotor 4 5 Fit the pump cover with a new gasket previously lubricated with petroleum jelly grease...

Page 228: ...INDEX OF TOPICS INJECTION INJEC...

Page 229: ...This is an integrated ignition and injection system Injection is indirect in the manifold through an electro injector Injection and ignition are timed on the 4 stroke cycle using a tone wheel keyed on...

Page 230: ...e injector is connected by means of a pipe fitted with fast release fittings The pressure regulator is at the beginning of the circuit The fuel pump is controlled by the MIU control unit therefore the...

Page 231: ...ectric components operate with battery connected only when strictly required 4 When checking functions make sure that the battery voltage is over 12V 5 Before trying to start up check to make sure the...

Page 232: ...e likely to be due to the connections rather than the components Before searching the MIU system for failures check A Power supply a Battery voltage b If a fuse is blown c Remote controls d Connectors...

Page 233: ...ot use unsuitable instruments as they may damage the MIU control unit Instruments with definitions over 0 1V and 0 5 W must be used Precision must be greater than 2 Terminals setup TERMINAL LAYOUT Spe...

Page 234: ...rature Sensor 3 Electric fan remote control 4 HV coil 5 Fuel injector 6 Fuel pump 7 Lambda Probe 8 Injection load remote control 9 stand switch 10 Engine revolution sensor 11 Battery 12 Start up remot...

Page 235: ...ary in sulation Parameter reliability Coolant temperature Distribution timing injection start Intake air temperature End of compression pressure End of compression pressure Parameter reliability Coola...

Page 236: ...nition timing Correctness of the parameters Throttle valve position sensor Stepper Coolant temperature sensor Intake air temperature sensor Intake system cleaning Air filter Diffuser and throttle valv...

Page 237: ...nsor Stepper 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 Fue...

Page 238: ...ture Lambda Probe Power to spark plug Spark plug Shielded cap HV Cable HV Coil Intake system Air filter Filter housing seal Intake sleeve seal Parameter reliability Throttle valve position signal Cool...

Page 239: ...for the cylinder base gas ket Selecting the thickness for the cylinder base gas ket Fuel supply system The fuel supply circuit includes the electric pump the filter the pressure regulator the electro...

Page 240: ...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 t...

Page 241: ...Remove the MIU control unit connector Remove throttle control retainer SCARABEO 500 Injection INJEC 241...

Page 242: ...8 Battery 9 Fuse 30 A 10 Fuse 10 A 11 Fuse 15 A 12 Key switch contacts 13 Key remote control switch relay When switched to ON the fuel pump starts to rotate for 2 seconds and then stops With engine o...

Page 243: ...trol 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 continu...

Page 244: ...he efficiency of the ground line of the fuel pump by measuring the continuity between the pump connector Blue cable system side and the ground connection If upon switching to ON the pump continues to...

Page 245: ...rate of approximately 1 L Make the pump turn with the active diagnosis on the palm top computer Using a pair of long flat needle nose pliers choke the fuel pipe making the pressure stabilise at approx...

Page 246: ...he 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 Injection SCARABEO 500 IN...

Page 247: ...ontrol 8 Battery 9 Fuse 30 A 10 Fuse 10 A 11 Fuse 15 A 12 Key switch contacts 13 Key remote control switch relay When switched to ON the fuel pump starts to rotate for 2 seconds and then stops With en...

Page 248: ...trol 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 continu...

Page 249: ...ntrol unit connected check there is voltage between the Red Brown cable of the injector connector and the ground connection With injector disconnected and the injector load remote control disconnected...

Page 250: ...ry Activate the fuel pump with the active diagnosis Check that within 15 seconds approx 70 cm of fuel is delivered at a regulation pressure of about 3 BAR Specific tooling 020480Y Fuel pressure check...

Page 251: ...13 15 is between 100 and 150 Ohm at an engine temperature of about 20 Disconnect the fuel pump connector Start the en gine and wait for it to stop With the wiring con nected to the control unit and t...

Page 252: ...e 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 insulated from the...

Page 253: ...ngine at idle speed it is optimised to stabilise the speed at 1500 100 rpm Magnetisation time The coil magnetisation time is controlled by the control unit The power of the ignition is increased durin...

Page 254: ...the remote control base and check the continuity of the Red Yellow cable between pin 20 of the control unit and the remote control base NOTE CONTINUITY TESTS MUST BE CARRIED OUT WITH THE COMPONENTS D...

Page 255: ...sistance Electric characteristic Resistance 5 K If different values are measured 1 20K re place the shielded cap NOTE A SHIELDLESS SPARK PLUG CAP OR A MISSING SPARK PLUG CAN ADVERSELY AFFECT THE INJEC...

Page 256: ...stroboscopic light Proceed as follows Remove the external transmission cover as des cried in the Automatic transmission chapter Remove the cap to inspect the TDC reference found between the flywheel a...

Page 257: ...e engine position 1 spark 2 revs Check that the real values of revs and ignition advance match those measured using the diag nostic tester If the values do not correspond check distribution timing rpm...

Page 258: ...en pin 9 of the interface wiring and the Orange cable of the connector Specific tooling 020481Y Adaptor cable harness 020331Y Digital multimeter Zeroing the throttle Throttle valve position signal res...

Page 259: ...e control unit as a starting point of the mV value corresponding to the pre calibrated position To reset proceed as follows Connect the diagnostic tester Shift to ON Select the diagnostic tester funct...

Page 260: ...the oxygen content in the exhaust fumes The signal generated is not of the proportional but of the ON OFF type i e whether there is oxygen or not The probe is positioned on the exhaust manifold befor...

Page 261: ...trol 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 continu...

Page 262: ...h a direct voltage scale measuring down to 2V Place the multimeter probes between pins 4 and 11 With the engine running at idle speed check that the voltage oscillates between 0V and 1V With the throt...

Page 263: ...INDEX OF TOPICS SUSPENSIONS SUSP...

Page 264: ...ws 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 Safety circlip 13 Sealing gasket 14 Cap 15 Bushing 16 Left wheel h...

Page 265: ...liding 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 Left bearing 8 Left oil seal 9 Brake discs 10 Left spacer 11 Rig...

Page 266: ...h 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 Unscrew and remove the wheel bolt Remove the wheel...

Page 267: ...ium protection jaws Undo and remove the lower screw 1 and collect the washer Slide off the stem from the sleeve and collect the bushing Slide off the pumping member 2 from the stem and collect the spr...

Page 268: ...l seal 6 from the sleeve Slide off the washer 7 from the sleeve Slide off the bushing 8 from the sleeve Oil emptying NOTE BEFORE CARRYING OUT THE FOLLOWING OPERATIONS GET A CONTAINER WITH SUITABLE CAP...

Page 269: ...TURN IT OVER OR TILT IT TOO MUCH WHEN REMOVING IT Lower the cap 1 until the Seeger ring 2 can be removed Remove the Seeger ring 2 Remove the cap 1 together with the O ring Remove the spring 3 and wait...

Page 270: ...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 Undo and remove the internal screw of the stem prot...

Page 271: ...ng surface for scorings and or scratches These scorings can be eliminated by rubbing them with wet sandpaper grain 1 If the scorings are deep replace the stem Use a dial gauge to check that the stem b...

Page 272: ...nents with new ones O ring gasket on the cap 1 oil seal 2 dust guard 3 Refitting Place the sleeve in the vice fitted with aluminium protection jaws Fit the spacer 1 CAUTION BE EXTREMELY CAREFUL SO THA...

Page 273: ...Insert the oil seal Fit the snap ring Fit the dust guard Insert the pumping member and the spring in the stem SCARABEO 500 Suspensions SUSP 273...

Page 274: ...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 Pour fork oil into the wheel holder stem sl...

Page 275: ...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 SCARABEO 500 Suspensions SUSP 275...

Page 276: ...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 Suspensions SCARABEO 500 SUSP 276...

Page 277: ...llect the two shim washers 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 clam...

Page 278: ...ove 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 Suspensions SCARABEO 500 SUSP...

Page 279: ...Unscrew and remove the two front nuts fixing the muffler supporting plate Remove the muffler supporting plate SCARABEO 500 Suspensions SUSP 279...

Page 280: ...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 Suspensions SCARABEO 500 SUSP 280...

Page 281: ...INDEX OF TOPICS BRAKING SYSTEM BRAK SYS...

Page 282: ...TARDING VALVE LOCATED UNDER THE HEADLAMP Operating the right front brake lever exerts pressure on the front right brake calliper Operating the left rear brake lever through the distribution valve exer...

Page 283: ...Washer 18 Pads torques 19 Calliper service kit 20 Rear brake calliper 21 Rear calliper support 22 M8X40 TE flanged screw 23 Rear calliper distribution pipe 24 Oil pipe screw 25 10x14x1 6 Washer 26 Pad...

Page 284: ...ecommended product Recommended products Loctite 243 Medium strength threadlock Locking torques N m Front brake calliper fixing screw 25 If the calliper is disconnected from the brake pipe CAUTION ALWA...

Page 285: ...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 Check the thickness of the friction ma terial Replace if the...

Page 286: ...D INSIDE THE CALLIPER Refitting To fit follow the removal steps but in reverse order and tighten the locking screws to the prescribed torque using the recommended product Recommended products Loctite...

Page 287: ...NGER COULD GO OUT OF ITS SEAT RESULTING IN BRAKE FLUID LEAKAGE CAUTION ALWAYS REPLACE BOTH PADS AND MAKE SURE THEY ARE CORRECTLY POSITIONED IN SIDE THE CALLIPER Check the thickness of the friction ma...

Page 288: ...tion material CAUTION ALWAYS REPLACE BOTH PADS AND MAKE SURE THEY ARE CORRECTLY POSITIONED INSIDE THE CALLIPER Refitting Fit two new brake pads Fit the spring CAUTION THE ARROW STAMPED ON THE SPRING M...

Page 289: ...several times keeping it completely operated afterwards 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 ma...

Page 290: ...stroke Repeat the operation until the fluid draining into the container is complete ly free of air bubbles NOTE WHILE PURGING THE HYDRAULIC SYSTEM FILL THE RESERVOIR WITH THE NECESSARY QUANTITY OF BR...

Page 291: ...in the bleed valve 1 of the front brake cal liper and insert the other end of this pipe into a container to collect the fluid Quickly press and release the brake lever of the specific brake calliper s...

Page 292: ...do and remove the two screws 1 and the bleed valve 2 Protect the three brake pipes to pre vent brake fluid spilling Undo and remove the two screws 3 fixing the distribution mechanism Remove the distri...

Page 293: ...INDEX OF TOPICS COOLING SYSTEM COOL SYS...

Page 294: ...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 M5 Clip 12 M5X12 TE flanged screw 13 Threaded cap 14...

Page 295: ...ystem has cooled down since small leaks may not be visible due to evaporation The water pump is provided with a drainage hole in case of leaks from the cooling system mechanical seal or from the shaft...

Page 296: ...with the ex pansion tank filler Loosen the bleed pipe and start the en gine Keep it open until the air has been fully vented Screw the bleed screw again Stop the engine Restore the level into the expa...

Page 297: ...ENGINE IS COLD Remove the water pump cover shown in the figure by loosening the six fixing screws Follow the instructions described in the Engine Water pump Chapter to check the pump Once the fault ha...

Page 298: ...s more visible If this occurs clean the housing and then check tightness again for trips over 1500 km If seeping persists or in case there are true leaks replace the ceramic seal To carry out these op...

Page 299: ...2 Check the head gasket seal see the Thermal group and Timing system chapter SCARABEO 500 Cooling system COOL SYS 299...

Page 300: ...INDEX OF TOPICS CHASSIS CHAS...

Page 301: ...1 and the saddle will open automatically Insert the key in the key lock and press down The glove box opens automati cally Pull the left lever to open the saddle manually Lift the saddle Remove the cen...

Page 302: ...lease the control cable and the sad dle unlocking cable Remove the connector Undo and remove the two fixing screws Remove the saddle opening system Instrument panel Remove the front headlight assembly...

Page 303: ...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 SCARABEO 500 Chassis CHAS 303...

Page 304: ...gether with the instrument panel Headlight assy Undo and remove the screw fixing the headlamp front cowl Remove the headlamp front cowl Slide off the upper cap from the tongues to remove it CAUTION PR...

Page 305: ...r screw NOTE Repeat the same procedure on the opposite side turning the handlebar fully to the left Turn the handlebar completely to the right and remove the lower screw Slightly lift the legshield lo...

Page 306: ...tor the horn the relay the fall sensor the antitheft control unit Knee guard Remove the legshield Remove the four screws 1 placed under the shield Remove the four screws 2 two per side inside the whee...

Page 307: ...est 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 SCARABEO 500 Chassis CHA...

Page 308: ...he rear mudguard and collect the two washers NOTE UPON REFITTING PAY ATTENTION TO THE LENGTH OF THE FIXING SCREWS THE REAR SCREW IS SHORTER Undo and remove the oil scavenge flange fixing screw Slide t...

Page 309: ...est the vehicle on its centre stand Working on both sides open the pas senger footrest Working on both sides undo and re move the three screws fixing the foot rest Working on both sides remove both fo...

Page 310: ...ws 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 Undo and remove the two front screws fi...

Page 311: ...ws 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 NOTE UPON REFITTING PAY ATTENTION THAT THE CENT...

Page 312: ...rews 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 th...

Page 313: ...ws fixing the battery cover Remove the battery protection cover Remove the tail section Remove the saddle Disconnect the electrical connector Disconnect the saddle opening ac tuator control cable Slid...

Page 314: ...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...

Page 315: ...e 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 SCARABEO 500 Ch...

Page 316: ...t 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 Heat protection cover 8 Washer 9 Plate C...

Page 317: ...emove the footrest Remove the stem covers Remove the front mudguard by undo ing the four internal fixing screws Undo and remove the two spoiler front fixing screws Disconnect the electric connection a...

Page 318: ...sides undo and re move the screw of the rear lower sup porting cross member Remove the cross member Working on both sides undo and re move the two screws fixing the front lower support cross member R...

Page 319: ...e 3 Unscrew and remove the two upper screws 1 of the expansion tank Open the glove box Undo the lower screw 2 of the ex pansion tank through the glove box hole Lift the expansion tank and disconnect t...

Page 320: ...Remove the screw 1 placed under each footrest Remove the shield back plate Remove the two screws 2 Chassis SCARABEO 500 CHAS 320...

Page 321: ...INDEX OF TOPICS PRE DELIVERY PRE DE...

Page 322: ...astic parts fixing screws Electrical system Main switch Lights high beam lights low beam lights tail lights front and rear and their warning lights Headlight adjustment according to regulations in for...

Page 323: ...CONTACT WITH EYES OR SKIN WASH ABUNDANTLY WITH WATER FOR APPROX 15 MIN AND SEEK IMMEDIATE MEDICAL ATTENTION IF ACCIDENTALLY SWALLOWED IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR VEGETABLE OIL SEEK...

Page 324: ...pection Hydraulic braking system Stroke of the brake levers Clutch Check for correct operation Engine Check for correct general operation and absence of abnormal noise Other Document check Check for c...

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APRILIA SCARABEO 500 - 2008, Service Station Manual

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