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GENERAL TECHNICAL INFORMATION

2 - 11

SCARABEO 500

DESCRIPTION

QUANTITY

SCREW /

NUT

TIGHTENING

TORQUE

SETTINGS

(Nm

)

NOTES

CENTRE CHASSIS ASSY

Case to frame fastening

6 TBEI screw M6X16

Rh/Lh platform to Rh/Lh rider platform connection plate
fastening

4 TBEI screw M5X12

Rh/Lh platform to radiator cowl fastening

3 TBEI screw M5x16

Inner shield to side shield halves and tunnel fastening

TCB screw

5.55X22

Bag hook fastening

2 TCB screw 4.2X25

Seat hinge to seat fastening

Nut M6

Spark plug seat cover fastening

TCB screw

5.5X15.9

Spark plug seat cover fastening

1 TCB screw 4.2X16

Rh/Lh multipurpose net to shield fastening

SELF-TAPPING

screw 3.9X14

Glove compartment door frame to door fastening

Screw 3.9X10

1,5

Plate to glove compartment door fastening

Screw 3.9X10

1,5

Plate to fuel filler flap fastening

SELF-TAPPING

screw 3.9X14

Glove compartment door to shield fastening

SELF-TAPPING

screw 3.9X14

Fuel filler flap to tunnel fastening

SELF-TAPPING

screw 3.9X14

1,5

FRONT CHASSIS ASSY

Air breather grid to rh shield half fastening

SELF-TAPPING

screw 3.9X14

Air breather grid to lh shield half fastening

SELF-TAPPING

screw 3.9X14

Shield half to rh radiator cowl fastening

3 TCB screw 4.2X16

Shield half to lh radiator cowl fastening

3 TCB screw 4.2X16

Tunnel fastening

TCB screw

5.55X22

Front mudguard fastening

TE screw M6x16

Содержание SCARABEO 500

Страница 1: ...www serviceaprilia com workshopmanual Scarabeo 500 1325 6 05 2006 00 8181024 UK...

Страница 2: ...INTRODUCTION 0 1 SCARABEO 500 INTRODUCTION 0...

Страница 3: ...INTRODUCTION 0 2 SCARABEO 500 SUMMARY 0 1 INTRODUCTION 3 0 1 1 FOREWORD 3 0 1 2 REFERENCE MANUALS 4 0 1 3 ABBREVIATIONS SYMBOLS CONVENTIONS 5...

Страница 4: ...modifications will be entered in subsequent editions of the manual Should you need assistance or clarifications about the inspection and repair procedures please contact the aprilia SERVICE DEPT they...

Страница 5: ...SPARE PARTS CATALOGUE aprilia part description 6836 CHASSIS WORKSHOP MANUAL aprilia part description 8181020 8181021 8181022 8181023 8181024 ENGINE TECHNICAL MANUAL aprilia part description 8140868 8...

Страница 6: ...rhead Camshaft ECU Electronic Control Unit rpm revolutions per minute HC unburnt hydrocarbons ISC Idle Speed Control ISO International Standardisation Organisation kg kilograms kgm kilograms per metre...

Страница 7: ...ight side SAE Society of Automotive Engineers TEST diagnostic check T B E I crown head Allen screw T C E I cheese head Allen screw T E hexagonal head T P flat head screw TSI Twin Spark Ignition UPSIDE...

Страница 8: ...GENERAL INFORMATION 1 1 SCARABEO 500 GENERAL INFORMATION 1...

Страница 9: ...ANUAL 3 1 1 1 CONVENTIONS USED IN THE MANUAL 3 1 1 2 SAFETY WARNINGS 4 1 2 GENERAL RULES 5 1 2 1 BASIC SAFETY RULES 5 1 3 DANGEROUS ELEMENTS 8 1 3 1 WARNINGS 8 1 4 RUNNING IN 11 1 4 1 RUNNING IN 11 1...

Страница 10: ...left are referred to the rider seated on the vehicle in the normal riding position Motorcycle operation and basic maintenance are covered in the OWNER S MANUAL In this manual any variants are identif...

Страница 11: ...e a personal injury hazard Non compliance with the indications given in the messages preceded by this symbol may result in serious risks for your and other people s safety and for the vehicle DANGER I...

Страница 12: ...e after the engine has been stopped Before handling these components wear insulating gloves or wait until the engine and the exhaust system have cooled down USED GEARBOX AND FORK FLUIDS DANGER Wear la...

Страница 13: ...is suitable for the type of battery used GENERAL PRECAUTIONS AND INFORMATION Follow these instructions closely when repairing disassembling or reassembling the motorcycle or its components DANGER Usin...

Страница 14: ...ate the bearings abundantly before assembly Make it a rule to check that all components you have fitted are correctly in place After repairing the motorcycle and after each service inspection perform...

Страница 15: ...cant can lead to the engine or gearbox seizure thus causing serious accidents personal injury or even death Gear fluid may cause serious damage to the skin if handled daily and for long periods Wash y...

Страница 16: ...edical advice DO NOT RELEASE BRAKE FLUID INTO THE ENVIRONMENT KEEP AWAY FROM CHILDREN When handling brake fluid take care not to spill it onto plastic or paint finished parts or they will damage DANGE...

Страница 17: ...fferent specifications The protection degree is written on the label WARNING Use nitrite free antifreeze and corrosion protectant fluids only with a protection until at least 35 C 31 F TYRES WARNING I...

Страница 18: ...t 1000 km 621 mi of running in is it possible to obtain the best acceleration performance from the vehicle Keep to the following indications Do not open the throttle completely if the speed is low bot...

Страница 19: ...ion NOTE Altering the vehicle identification numbers is a legal offence Altering the frame number invalidates the warranty FRAME NUMBER The frame number is stamped on the front frame open the glove co...

Страница 20: ...GENERAL TECHNICAL INFORMATION 2 1 SCARABEO 500 GENERAL TECHNICAL INFORMATION 2...

Страница 21: ...1 2 SCHEDULED MAINTENANCE CHART 5 2 1 3 LUBRICANT CHART 7 2 1 4 TIGHTENING TORQUE SETTINGS 8 2 1 5 ARRANGEMENT OF THE MAIN ELEMENTS 13 2 1 6 INSTRUMENT PANEL OPERATION 15 2 2 SCHEDULED MAINTENANCE 18...

Страница 22: ...oil filter and pressure relief by pass valve THROTTLE BODY Model 38 mm 1 50 in and single injector Throttle 39 mm 1 53 in FUEL SYSTEM Type Electronic injection with electric fuel pump Fuel Unleaded p...

Страница 23: ...2 3 bar IGNITION Type C D I induction type Spark advance Variable managed by control unit SPARK PLUG Standard CHAMPION RG6YC As an alternative NGK CR7EKB Spark plug gap 0 7 0 8 mm 0 028 0 031 in ELEC...

Страница 24: ...drain Steering check Injection system tubes sealing visual check EVERY 5000 km 3107 mi Engine oil check level top up Brake pads check for wear At 10000 km 6214 mi 30000 km 18641 mi 50000 km 31068 mi...

Страница 25: ...lter check Engine oil filter change Valve clearance check Electric system and battery check Coolant level check Brake fluid level check Engine oil change Brake pads check for wear Converter rollers sl...

Страница 26: ...W 67 of volume Bearings and other lubrication points RECOMMENDED GREASE SM2 As an alternative to recommended grease use top brand rolling bearing grease that will resist a temperature range of 30 C 22...

Страница 27: ...ter motor cable fastening 1 Nut M6 5 Rear brake calliper mount fastening 2 TE screw M8X50 25 Rear brake disc to hub fastening 5 Nuts M6X1 12 Muffler plate to engine fastening 2 Nut 50 Engine to air bo...

Страница 28: ...ator hose ties fastening 2 Tie 3 REAR WHEEL ASSY Rear wheel to hub fastening 5 TE screw M8x40 35 Rear wheel fastening 1 Nut 120 REAR SUSPENSION ASSY Rh Lh shock absorber support fastening 4 Nut M8 25...

Страница 29: ...o relay fastening 1 Nut M6 5 Battery cable to starter motor relay fastening 1 Nut M6 5 Antitheft system control unit to frame fastening 3 SELF TAPPING screw 3 9X14 1 Connector closure to antitheft sys...

Страница 30: ...6 1 Rh Lh multipurpose net to shield fastening 4 SELF TAPPING screw 3 9X14 1 Glove compartment door frame to door fastening 4 Screw 3 9X10 1 5 Plate to glove compartment door fastening 2 Screw 3 9X10...

Страница 31: ...screw M5X12 2 Radiator cowl to frame fastening 2 TBEI screw M6X16 8 Radiator cowl to frame fastening 1 TBEI screw M6X16 4 Rh Lh turn indicator cover fastening 4 4 Washers Cover fastening 2 TCB screw 5...

Страница 32: ...NGEMENT OF THE MAIN ELEMENTS Key 1 Expansion tank 2 Coolant expansion tank cap 3 Integrated brake fluid reservoir 4 Air filter 5 Transmission cover 6 Left passenger footpeg 7 Centre stand 8 Side stand...

Страница 33: ...RABEO 500 Key 1 Passenger grab handle 2 Front brake fluid reservoir 3 Seat release lever 4 Fuel tank filler plug 5 Fuel tank 6 Battery 7 Auxiliary fuse carrier 8 Main fuse carrier 9 Right passenger fo...

Страница 34: ...ator 7 service warning indicator 8 fuel level indicator 9 The diagram shows the sequence of available functions Pulse means pressing the key and holding it for a certain time between 0 5 sec and 3 sec...

Страница 35: ...ge the Service icon is fixed on until it is reset SERVICE RESET The service icon is reset by holding the MODE button for more than 10 seconds when the key is turned on the instrument panel will not sh...

Страница 36: ...he same time as the turn indicators FUEL RESERVE This light should use an orange LED that turns on when the vehicle is using the fuel reserve OIL ALARM This light should use a red LED that indicates o...

Страница 37: ...brake calliper BLEEDING THE FRONT BRAKE NOTE The following procedure applies to both front brake callipers Remove the rubber protection cap from bleed valve 1 Slide a clear plastic tube onto front ca...

Страница 38: ...ber cap BLEEDING THE BRAKE FORCE DISTRIBUTION NOTE If the rear brake lever still feels spongy after bleeding the front and rear braking systems or in case the brake force distributor is replaced proce...

Страница 39: ...s 1 Remove the air box cover complete with filter Check the filtering element and change it if required CLEANING WARNING Do not use petrol or inflammable solvents to wash the filtering element in orde...

Страница 40: ...nd MAX notches MIN minimum level MAX maximum level If not so Loosen the filler plug 1 by turning it anticlockwise without removing it Wait a few seconds in order to release any residual pressure Unscr...

Страница 41: ...t into the filling hole Withdraw the plug dipstick 1 again and read the oil level on the dipstick itself Level is correct when it reaches approximately the first notch above the spot If necessary prov...

Страница 42: ...ug dipstick 1 Set a collector tank with a capacity of more than 300 cu cm 18 3 cu in under drain screw 2 Loosen and remove the drain screw After draining all transmission fluid tighten the drain screw...

Страница 43: ...tick 1 completely screwing it into the filling hole 2 Withdraw the plug dipstick 1 again and read the oil level on the dipstick itself MAX maximum level MIN minimum level The level is correct if the o...

Страница 44: ...crew and remove the oil cartridge filter WARNING Used oil contains substances that are very dangerous for the environment Dispose of used oil in accordance with applicable regulations Unscrew and remo...

Страница 45: ...FUEL SYSTEM 3 1 SCARABEO 500 FUEL SYSTEM 3...

Страница 46: ...FUEL SYSTEM 3 2 SCARABEO 500 SUMMARY 3 1 FUEL TANK 3 3 1 1 FUEL SUPPLY SYSTEM DIAGRAM 3 3 1 2 REMOVING THE TANK 4 3 2 AIR FILTER 6 3 2 1 REMOVING THE AIR BOX 6 3 3 DIAGNOSIS 8 3 3 1 AXONE 8...

Страница 47: ...UPPLY SYSTEM DIAGRAM Key 1 Fuel tank 2 Tank plug 3 Fuel level sensor 4 Fuel pump 5 Fuel pump ring nut seal 6 Fuel pump ring nut 7 Heat shield 8 Washer 9 Plate 10 Rubber block 11 Clip M6 12 Flanged Hex...

Страница 48: ...guard by loosening the four inner retaining screws Loosen and remove the two spoiler front screws Disconnect electric connection and fuel delivery and inlet lines Working on the left side disconnect t...

Страница 49: ...side loosen and remove the two screws securing the front lower support crosspiece Remove the crosspiece Loosen and remove the tank front retaining screw Loosen and remove the tank rear retaining scre...

Страница 50: ...loosen and remove the two side securing screws from rear mudguard and collect both washers NOTE On refitting pay special attention to the length of the securing screws as the rear screw is shorter Loo...

Страница 51: ...FUEL SYSTEM 3 7 SCARABEO 500 Loosen the screw of the air filter inner support Loosen the intake manifold clamp Remove the bleeder Remove the air box...

Страница 52: ...he ECU is empty not mapped it is necessary to upload the suitable mapping see note concerning mapping parameter Aprilia software Meaningless field Revision number XX Engine 500 cc Single cylinder engi...

Страница 53: ...missed since the beginning of the trip 0 1 1 if many teeth are missing Engine phase number within which just a tooth was missed since the beginning of the trip 0 1 1 if one tooth is missing Actual to...

Страница 54: ...ecord STO The next time Axone is connected to the ECU the errors in the historical record STO will no longer be displayed Fuel pump The device is activated in the event that the device is not activate...

Страница 55: ...ror will not be displayed From the Adjustable parameters page it is possible to reset the throttle position sensor initialise the ECU i e reset the throttle position sensor reset the stepper idle moto...

Страница 56: ...ENGINE 4 1 SCARABEO 500 ENGINE 4...

Страница 57: ...ENGINE 4 2 SCARABEO 500 SUMMARY 4 1 ENGINE 3 4 1 1 REMOVING THE ENGINE FROM THE FRAME 3 4 1 2 INSTALLING THE ENGINE 17...

Страница 58: ...the vehicle on the centre stand Remove the tail guard see REMOVING THE TAIL GUARD Remove the helmet compartment see REMOVING THE HELMET COMPARTMENT NOTE Before proceeding with the operations take a c...

Страница 59: ...ight side loosen and remove the two side securing screws from rear mudguard and collect both shims Working on the left side loosen and remove the two side securing screws from rear mudguard and collec...

Страница 60: ...CARABEO 500 Loosen and remove the securing screw from the oil recovery flange Slide the flange out of its seat Loosen the screw of the air filter inner support Loosen the intake manifold clamp Remove...

Страница 61: ...500 Remove the air box Set up the lift hoist and fasten the vehicle suitably with the lifting slings Loosen and remove the upper securing screw of the right shock absorber and collect the nut Move the...

Страница 62: ...CARABEO 500 Loosen and remove the lower securing screw of the left shock absorber and collect the nut Move the shock absorber away Loosen the adjusters and slide throttle cables out Remove air tempera...

Страница 63: ...ore proceeding with the operations take a container of adequate capacity to collect possible coolant spillage Loosen the thermostatic valve clamp Remove the spark plug cap Remove the injector control...

Страница 64: ...ENGINE 4 9 SCARABEO 500 Loosen and remove the securing screw of the fuel lines and collect the washer Disconnect the coolant temperature sensor Remove the clamp Disconnect the lambda sensor connector...

Страница 65: ...EO 500 Disconnect the stepper motor connector Disconnect the throttle position sensor Loosen and remove the securing screw of the ground wires Open cable guide Release the oil pressure sensor cable fr...

Страница 66: ...O 500 Disconnect the oil pressure sensor Working on both sides loosen and remove the side securing screw Slightly lift the central fairing Remove and disconnect the generator connector Loosen the exha...

Страница 67: ...ve the securing screw from the exhaust pipe clamp Push in the exhaust and remove the upper pin securing the clamp Loosen and remove the securing screw from the exhaust pipe Remove the exhaust pipe Rem...

Страница 68: ...4 13 SCARABEO 500 Have an assistant apply the rear brake while you loosen and remove the rear securing nut from the plate Loosen and remove the two front securing nuts from the plate Remove the suppor...

Страница 69: ...de Loosen and remove the five screws securing the wheel Remove the wheel Loosen and remove the securing screw from the rear brake line collect the spacer Loosen and remove the two securing screws from...

Страница 70: ...500 Loosen and remove the securing nut from the positive cable Release the positive cable Working on the right side loosen and remove the securing nut from the swinging arm shaft and collect the wash...

Страница 71: ...n and remove the securing nut from the connecting rod and collect the washer and the silent block Loosen the pin and collect the washer Release slings from hoist supporting the vehicle rear end and re...

Страница 72: ...tening holes are aligned Fit the washer between swingarm shaft and frame during this procedure Working on the left side fit the shaft Completely tighten the shaft fully home Working on the right side...

Страница 73: ...RABEO 500 Set the silent block with washer and tighten the nut Set the positive cable Tighten the nut Fit the protection element Fit the rear brake calliper Tighten the two securing screws on the rear...

Страница 74: ...INE 4 19 SCARABEO 500 Set the rear brake line guide and spacer then tighten its screw Fit the wheel Tighten the five wheel screws Fit the support plate Fit and tighten the two front nuts on support pl...

Страница 75: ...ENGINE 4 20 SCARABEO 500 Fit the shim Fit the plate rear nut Have an assistant apply the rear brake while you tighten the rear securing nut on the plate Fit the cap Fit the safety split pin...

Страница 76: ...w on the exhaust pipe Fit and tighten the securing screw on the exhaust pipe clamp Push in the exhaust and fit the upper pin securing the clamp Fasten the exhaust manifold clamp Slightly lift the cent...

Страница 77: ...4 22 SCARABEO 500 Working on both sides fit and tighten the side securing screw Connect the oil pressure sensor Fit the oil pressure sensor cable Secure the two clamps Connect the throttle position s...

Страница 78: ...ENGINE 4 23 SCARABEO 500 Connect the stepper motor connector Connect the lambda sensor connector Fasten the clamp Connect the coolant temperature sensor Fit the fuel lines...

Страница 79: ...SCARABEO 500 Fit the hose stop washer and then fit and tighten the fuel lines retaining screw Fit the injector control sensor Fit the spark plug cap Fit the coolant hose Tighten the clamp on thermost...

Страница 80: ...ENGINE 4 25 SCARABEO 500 Fit the air temperature sensor Fit throttle cables and tighten the adjusters Install the shock absorber Set the shock absorber screw and tighten the nut...

Страница 81: ...ENGINE 4 26 SCARABEO 500 Install the shock absorber Set the right shock absorber screw and tighten the nut Fit the air box Fit the bleeder Fit the intake manifold and tighten the clamp...

Страница 82: ...ENGINE 4 27 SCARABEO 500 Fit and tighten the screw on air filter internal support Fit the flange Fit and tighten the securing screw from the oil recovery flange Fit the mudguard...

Страница 83: ...side securing screws on rear mudguard with washers Working on the right side fit and tighten the two side securing screws on rear mudguard with shims Fit the hose Tighten the clamp Fill up the coolin...

Страница 84: ...ENGINE 4 29 SCARABEO 500 Set the tail guard see REMOVING THE TAIL GUARD...

Страница 85: ...CYCLE PARTS 5 1 SCARABEO 500 CYCLE PARTS 5...

Страница 86: ...STEM 18 5 2 1 REMOVING THE EXHAUST SYSTEM 18 5 3 FRONT WHEEL 20 5 3 1 FRONT WHEEL DIAGRAM 20 5 3 2 REMOVING THE FRONT WHEEL 21 5 4 REAR WHEEL 22 5 4 1 REAR WHEEL DIAGRAM 22 5 4 2 REMOVING THE REAR WHE...

Страница 87: ...this you can either use the supplied remote control and press the button 1 to automatically open the seat or insert and press the key in the switch The glove compartment opens automatically Pull the...

Страница 88: ...tely turn the handlebar to the right and remove the bottom screw NOTE Proceed in the same way on the opposite side turning handlebar to the left Slightly raise the cover lower end and remove it by sli...

Страница 89: ...d remove the three screws from footrests NOTE The rear screw is longer than the front ones ensure to refit it in the correct position Working on either side remove both passenger footrests Raise the s...

Страница 90: ...S 5 6 SCARABEO 500 Loosen and remove the two tail guard front screws Working on either side loosen and remove the two side lower screws Loosen and remove the four screws from grab handle cover Remove...

Страница 91: ...s securing the grab handle NOTE The centre screw is longer than the side ones ensure to refit it in the correct position Remove the tail light top cover Loosen and remove the two tail guard rear screw...

Страница 92: ...CYCLE PARTS 5 8 SCARABEO 500 Disconnect the three connectors Remove the tail guard together with tail light...

Страница 93: ...Loosen and remove the two battery cover screws Remove the battery cover Remove the tail guard see REMOVING THE TAIL GUARD Remove the seat see REMOVING THE SEAT Disconnect the electrical connector Disc...

Страница 94: ...500 Slide out cables from helmet compartment Loosen and remove the screw securing the helmet compartment light switch Disconnect the two connectors of helmet compartment light switch Remove the helme...

Страница 95: ...CARABEO 500 Loosen and remove the two front screws Working on either side loosen and remove the side screws Loosen and remove the two rear screws Loosen and remove the screws securing helmet compartme...

Страница 96: ...CYCLE PARTS 5 12 SCARABEO 500 Remove the helmet compartment...

Страница 97: ...e the tail guard see REMOVING THE TAIL GUARD Remove the inner front cover see REMOVING THE TANK Remove the centre tunnel see REMOVING THE TANK Loosen and remove the two bottom screws Remove the plasti...

Страница 98: ...ing on either side loosen and remove the two screws securing the front instrument panel fairing Remove the front instrument panel fairing Loosen and remove the two instrument panel top screws Disconne...

Страница 99: ...en and remove the securing screw from the headlight frame Remove the headlight frame Remove the top shell disengaging the tabs WARNING Proceed with care Do not damage the tabs and or their seats Loose...

Страница 100: ...CYCLE PARTS 5 16 SCARABEO 500 Move aside the headlight and disconnect the connector Carefully remove the headlight avoiding damages...

Страница 101: ...T RELEASING SYSTEM Remove the central inspection cover see REMOVING THE TAIL GUARD Release the control cable Release the control cable and the seat releasing cable Remove the connector Unscrew and rem...

Страница 102: ...1 REMOVING THE EXHAUST SYSTEM Loosen the exhaust manifold clamp Loosen and remove the securing screw from the exhaust pipe clamp Push in the exhaust and remove the upper pin securing the clamp Loosen...

Страница 103: ...5 19 CYCLE PARTS SCARABEO 500 Remove the exhaust pipe...

Страница 104: ...FRONT WHEEL 5 3 1 FRONT WHEEL DIAGRAM Key 1 Wheel shaft 2 Odometer sensor 3 Right oil seal 4 Right bearing 5 Wheel 6 Inner spacer 7 Left bearing 8 Left oil seal 9 Brake discs 10 Left spacer 11 Right...

Страница 105: ...side loosen and remove the two screws from brake calliper Slide off both callipers from the front brake discs Place the vehicle on the front stand OPT Loosen the wheel shaft screw on right fork leg L...

Страница 106: ...CYCLE PARTS 5 22 SCARABEO 500 5 4 REAR WHEEL 5 4 1 REAR WHEEL DIAGRAM Key 1 Complete wheel 2 Split pin 3 Cap 4 Nut 5 External spacer 6 Screw 7 Washer 8 Washer 9 Inner spacer 10 Wheel hub 11 Brake disc...

Страница 107: ...o side securing screws from rear mudguard and collect both shims Loosen the exhaust manifold clamp Loosen and remove the securing screw from the exhaust pipe clamp Push in the exhaust and remove the u...

Страница 108: ...CYCLE PARTS 5 24 SCARABEO 500 Remove the safety split pin Remove the cap Have an assistant apply the rear brake while you loosen and remove the rear securing nut from the plate...

Страница 109: ...ABEO 500 Loosen and remove the two front securing nuts from the plate Remove the support plate NOTE Place a suitable support on the vehicle lower side Loosen and remove the five screws securing the wh...

Страница 110: ...CYCLE PARTS 5 26 SCARABEO 500 5 5 BRAKING SYSTEM 5 5 1 BRAKING SYSTEM DIAGRAM...

Страница 111: ...12 Brake line from m cylinder to brake force distributor 13 Drilled screw 14 Bleeder 15 Bleeder cap 16 Oil line screw 17 Washer 10X14X1 6 18 Pads sets 19 Kit for calliper ovhl 20 Rear brake calliper 2...

Страница 112: ...oth brake callipers Release the retainer 2 Slide off the two pins 3 Slide out the brake pads WARNING Always change both pads and ensure they are correctly in place inside the calliper Do not reverse r...

Страница 113: ...Slide the pin Remove the spring WARNING On spring is an arrow that should always be pointing in the direction of travel Slide out the brake pads WARNING Always change both pads and ensure they are co...

Страница 114: ...unit keeping it connected to the wiring Drain the braking system Loosen and remove the two screws 1 and bleed valve 2 collect the gaskets NOTE Mark the brake lines to ensure correct position at reass...

Страница 115: ...be 2 Fork clamp screws 3 O ring 4 Snap ring 5 Seal plug 6 Spring 7 Damping rod 8 Counter spring 9 Buffer 10 Left slider 11 Dust seal 12 Safety snap ring 13 Seal 14 Washer 15 Bushing 16 Left sleeve 17...

Страница 116: ...icle front end using slings and a hoist Remove the front wheel see REMOVING THE FRONT WHEEL Loosen and remove the front brake line guide screw Loosen and remove the screw inside leg guard Remove the l...

Страница 117: ...5 33 CYCLE PARTS SCARABEO 500 Slacken the two fork leg retaining screws Remove the top circlip 2 Remove the outer sleeve 3 sliding it off from the bottom...

Страница 118: ...ity Set the sleeve in a vice WARNING The slider and sleeve assembly is filled with oil do not turn it upside down or excessively tilt it during disassembly Move down plug 1 until it is possible to rem...

Страница 119: ...5 35 CYCLE PARTS SCARABEO 500 Drain oil into the container pumping with the slider...

Страница 120: ...AINING OIL Set the slider in a vice with soft jaws aluminium Unscrew and remove the lower screw 1 collect the washer Slide the slider off the sleeve and collect the bushing Slide off the damper rod 2...

Страница 121: ...5 37 CYCLE PARTS SCARABEO 500 Remove the circlip 5 from sleeve Remove the oil seal 6 from sleeve Remove the washer 7 from sleeve Remove the shell 8 from sleeve...

Страница 122: ...500 5 6 5 FILLING OIL Set the slider and sleeve assembly in a vice with soft jaws aluminium Pour fork oil in the assembly WARNING Do not reuse oil that was previously drained Insert the spring Fit pl...

Страница 123: ...5 39 CYCLE PARTS SCARABEO 500 Move down plug 1 until it is possible to fit circlip 2 Fit circlip 2...

Страница 124: ...uckling using a dial gauge Replace the stanchion if buckled beyond the service limit Max allowed buckling 0 2 mm DANGER NEVER attempt to straighten a buckled stanchion as this would weaken the overall...

Страница 125: ...sleeve in a vice with soft jaws aluminium Fit spacer 1 WARNING Ensure that no foreign matter enters inside the sleeve and slider NOTE Before refitting the seals and bushings smear them with a film of...

Страница 126: ...CYCLE PARTS 5 42 SCARABEO 500 Fit the dust seal Install the damper rod and the spring in slider Install slider with bushing 2 in sleeve Tighten bottom screw 3 with washer Fill with oil see FILLING OIL...

Страница 127: ...COOLING SYSTEM 6 1 SCARABEO 500 COOLING SYSTEM 6...

Страница 128: ...COOLING SYSTEM 6 2 SCARABEO 500 SUMMARY 6 1 COOLING SYSTEM 3 6 1 1 COOLING SYSTEM DIAGRAM 3 6 1 2 CHANGING THE COOLANT 4 6 1 3 REMOVING THE EXPANSION TANK 5...

Страница 129: ...ric fan 8 Spacer bushing 9 Top rubber block 10 Bottom rubber block 11 Clip M5 12 Flanged Hex screw M5X12 13 Plug 14 Washer 6 6X18X1 6 15 Flanged Hex screw M6X20 16 Bushing 17 Flanged Hex screw M5X12 1...

Страница 130: ...lug to let the coolant flow out Drain the system FILLING Refit the hose Secure it with clamp Remove the central inspection cover Remove the rubber cap Slacken bleed valve and fit a tube set the other...

Страница 131: ...over see REMOVING THE FRONT COVER Detach breather tube 3 from expansion tank Loosen and remove the top screw 1 from expansion tank Open the glove compartment Loosen the bottom screw 4 from expansion t...

Страница 132: ...ELECTRICAL SYSTEM 7 1 SCARABEO 500 ELECTRICAL SYSTEM 7...

Страница 133: ...ELECTRICAL SYSTEM 7 2 SCARABEO 500 SUMMARY 7 1 ELECTRIC COMPONENTS 3 7 1 1 CHECKING THE ELECTRICAL COMPONENTS 3 7 1 2 WIRING DIAGRAM 5...

Страница 134: ...ELECTRICAL SYSTEM 7 3 SCARABEO 500 7 1 ELECTRIC COMPONENTS 7 1 1 CHECKING THE ELECTRICAL COMPONENTS...

Страница 135: ...00 Key 1 Bank angle sensor 2 30A Starter relay 3 30A relay with diode 4 Headlight 5 Tail light 6 Coil with cable and cap 7 Main fuses 8 ECU 9 Warning horn 10 Voltage regulator 11 150A Starter relay 12...

Страница 136: ...ELECTRICAL SYSTEM 7 5 SCARABEO 500 7 1 2 WIRING DIAGRAM...

Страница 137: ...trument panel 33 Engine air thermistor 34 Throttle sensor 35 Lambda sensor 36 Auxiliary injection relay 37 Main injection relay polarised 38 Stand switch 39 Fuel level sensor 40 Fuel pump 41 Spark plu...

Страница 138: ...aprilia via G Galilei 1 30033 Noale VE Italy tel 39 041 5829111 fax 39 041 5801674 www aprilia com...

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