APRILIA Scarabeo 50 I.E.-50 4T Workshop Manual
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APRILIA Scarabeo 50 I.E.-50 4T Workshop Manual

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SCARABEO 50 I.E. - 50 /100 4T
1118 2
02/2003-00
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Summary of Contents for APRILIA Scarabeo 50 I.E.-50 4T

  • Page 1 SCARABEO 50 I.E. - 50 /100 4T 1118 2 02/2003-00 workshopmanual...

  • Page 2: Foreword

    Scarabeo 100 4T 6631 Scarabeo 50 IE 5601 aprilia s.p.a. reserves the right to modify any of its mod- WARNING els in any manner at any time. When you find this symbol on the vehicle or in the This manual is protected by copyright in all countries. Re- vehicle, this indicates that a potential for serious per- production by any means, print or electronic, is prohibited.

  • Page 3: General Safety Rules

    Scarabeo 50 I.E.-50/100 4T GENERAL SAFETY RULES Always wear goggles when servicing the brake sys- tem with brake fluid. Brake fluid is extremely destruc- CARBON MONOXIDE tive to your eyes. If you should accidentally get brake If it is necessary to let the engine run in order to carry out fluid in your eyes, flush immediately with a large quan- some work, make sure that the area in which you are tity of cool clear water and seek professional medical...

  • Page 4: Precaution And General Informations

    – Use only original aprilia SPARE PARTS. Avoid the temptation to hold any hardware or other part of – Use the recommended lubricants.

  • Page 5: Electrical Connectors

    The table below shows tightening torques for screws and bolts with metric ISO threads, as is used in this vehicle. These are general values to be used if no specific value is given in this manual or other aprilia service literature. Tightening torques Screw...

  • Page 6: Your Service And Repair Manual

    Scarabeo 50 I.E.-50/100 4T HOW TO USEYOUR SERVICE AND REPAIR MANUAL ADVICE FOR CONSULTATION This manual is divided into chapters, each one of which corresponds to a category of main components. To consult them, see the general index, see p. 6 (TABLE OF CONTENTS).

  • Page 7: Table Of Contents

    Scarabeo 50 I.E.-50/100 4T CONTENTS CHECKING THE FUEL LEVEL GAUGE UNIT ....33 FOREWORD ............... 1 REMOVING THE FUEL LEVEL GAUGE UNIT ... 33 INTRODUCTION ..............1 REMOVING FUEL TANK ..........34 SAFETY WARNINGS ............1 REMOVING FUEL TANK ........34 GENERAL SAFETY RULES ..........
  • Page 8 Scarabeo 50 I.E.-50/100 4T REASSEMBLY ..............58 REAR WHEEL ..............60 DISASSEMBLY ..............60 CHECKING THE ENGINE FULCRUM AXIS ....61 IGNITION SWITCH / STEERING LOCK ......61 REMOVAL ................. 61 AIR CLEANER ............. 62 REMOVAL THE AIR FILTER ..........62 REMOVING THE COMPLETE AIR CLEANER CASING ................

  • Page 9: Technical Data

    Scarabeo 50 I.E.-50/100 4T TECHNICAL DATA DIMENSIONS Max. length 1905 mm (75 in) Max. width (at brake levers) 705 mm (27.7 in) Max. height (at rear view mirrors) 1270 mm (50.0 in) Seat height 780 mm (30.7 in) Wheel base 1250 mm (49.2 in) - 1256 mm (49.4 in) Min.
  • Page 10 Scarabeo 50 I.E.-50/100 4T FRAME Type split single tube with double cradle SUSPENSIONS Front hydraulically operated telescopic fork 80 mm (3.14 in) Stroke hydraulic single-shock absorber Rear Stroke 80 mm (3.14 in) BRAKES disc brake, Ø 220 mm (8.66 in) with hydraulic transmission Front disc brake, Ø...

  • Page 11: Tightening Torques Table

    Scarabeo 50 I.E.-50/100 4T TIGHTENING TORQUES TABLE DESCRIPTION ftlb FRAME ASSEMBLY Shock absorber-frame coupling M10 32.45 ENGINE MOUNT CONNECTING RODS ASSEMBLY Frame connecting rod nut M10 32.45 Engine connecting rod nut M10 32.45 FRONT SUSPENSION ASSEMBLY Pumping element-fork sleeve tightening screw M10 5.16 ENGINE ASSEMBLY Throttle body clamp screw M4...

  • Page 12: Tightening Torques Table

    Scarabeo 50 I.E.-50/100 4T TIGHTENING TORQUES TABLE DESCRIPTION ftlb FRAME ASSEMBLY Shock absorber-frame coupling M10 32.45 ENGINE MOUNT CONNECTING RODS ASSEMBLY Frame connecting rod nut M10 32.45 Engine connecting rod nut M10 32.45 FRONT SUSPENSION ASSEMBLY Pumping element-fork sleeve tightening screw M10 5.16 ENGINE ASSEMBLY Throttle body clamp screw M4...

  • Page 13: Tightening Torques Table

    Scarabeo 50 I.E.-50/100 4T TIGHTENING TORQUES TABLE DESCRIPTION ftlb FRAME ASSEMBLY Shock absorber-frame coupling M10 32.45 Footboard support M8 21,5 15.85 Footboard fastening M10 32.45 ENGINE MOUNT CONNECTING RODS ASSEMBLY Frame connecting rod nut M10 32.45 Engine connecting rod nut M10 32.45 STAND ASSEMBLY Stand screw M10...

  • Page 14: Lubricant Chart

    Scarabeo 50 I.E.-50/100 4T LUBRICANT CHART Engine oil (recommended): SUPERBIKE 4, SAE 5W - 40 or 4T FORMULA RACING, SAE 5W - 40. As an alternative to the recommended oil, it is possible to use other brands of oil with performance levels that meet or exceed the requirements of CCMC G-4, A.P.I.

  • Page 15: Regular Service Interval Chart

    Scarabeo 50 I.E.-50/100 4T REGULAR SERVICE INTERVALS CHART OPERATIONS TO BE CARRIED OUT BY THE aprilia Official Dealer (WHICH CAN BE CARRIED OUT EVEN BY THE USER) Every 4,000 km After running-in Every 8,000 km Components (2,500 km) [500 km (312 mi)]...
  • Page 16 Scarabeo 50 I.E.-50/100 4T REGULAR SERVICE INTERVALS CHART OPERATIONS TO BE CARRIED OUT BY THE aprilia Official Dealer Every 4,000 km After running-in Every 8,000 km Components (2,500 km) [500 km (312 mi)] (5,000 mi) or 24 months or 12 months...
  • Page 17 Scarabeo 50 I.E.-50/100 4T REGULAR SERVICE INTERVALS CHART OPERATIONS TO BE CARRIED OUT BY THE aprilia Official Dealer Every 6,000 km After running-in Every 12,000 km Components (3,750 km) [1,000 km (625 mi)] (7,500 mi) or 24 months or 12 months...

  • Page 18: Identification Data

    Scarabeo 50 I.E.-50/100 4T IDENTIFICATION DATA Please supply the frame number when you purchase spare parts. NOTE Do not obliterate or alter the identification numbers under any circumstance. This is illegal in all countries. In addition, alteration of the identification numbers invalidates the warranty.

  • Page 19: Arrangement Of The Main Elements

    6) Frame number cover 7) Front brake reservoir 8) Spark plug 9) Fuel tank 10) Passenger right footrest (in the countries where required) 11) Anti-theft hook (for the aprilia “Body-Guard” armored cable ARRANGEMENT OF THE MAIN ELEMENTS 1) Horn 2) Glove compartment...

  • Page 20: Arrangement Of The Instruments / Instruments And Indicators

    Scarabeo 50 I.E.-50/100 4T ARRANGEMENT OF THE INSTRUMENTS / INSTRUMENTS AND INDICATORS aprilia mph km/h 1) Electrical controls on the left side of the handlebar 2) Rear brake lever 3) Left rear-view mirror 4) Instruments and indicators mph km/h aprilia...

  • Page 21: Throttle

    Scarabeo 50 I.E.-50/100 4T THROTTLE CHECKING THE OPERATION OF THE THROTTLE CONTROL Carefully read p. 2 (GENERAL SAFETY RULES). WARNING Do not use your vehicle if it has a damaged, kinked or twisted throttle cable. This can interfere with the regular operation of the throttle, and cause the throttle to stick on.

  • Page 22: Adjusting The Throttle Control

    Scarabeo 50 I.E.-50/100 4T ADJUSTING THE THROTTLE CONTROL Carefully read p. 2 (GENERAL SAFETY RULES). NOTE Before carrying out any operation, check the correct functioning of the throttle control, see p. 20 (CHECKING THE OPERATION OF THE THROTTLE CONTROL). WARNING If the throttle sticks open, you will lose control of your vehicle and a serious accident could result.

  • Page 23: Fairings

    Scarabeo 50 I.E.-50/100 4T FAIRINGS REMOVING THE LUGGAGE RACK Carefully read p. 2 (GENERAL SAFETY RULES). ♦ Place the vehicle on the center stand. ♦ Remove the cover shown in the figure (1). ♦ Unscrew and remove the two screws (2). ♦...
  • Page 24 Scarabeo 50 I.E.-50/100 4T CAUTION Handle the plastic and painted components with care and avoid scraping or damaging them. ♦ Slightly pull outward and raise upward the front portion of the rear part of the fairing (7). ♦ Move the rear part of the fairing (7) backwards a few inches.

  • Page 25: Removing The Rear Mudguard

    Scarabeo 50 I.E.-50/100 4T REMOVING THE REAR MUDGUARD Carefully read p. 2 (GENERAL SAFETY RULES). ♦ Remove the rear part of the fairing, see p. 22 (RE- MOVING THE REAR PART OF THE FAIRING). ♦ Disconnect the number plate lamp cables. ♦...

  • Page 26: Removing The Front Cover

    Scarabeo 50 I.E.-50/100 4T REMOVING THE FRONT COVER Carefully read p. 2 (GENERAL SAFETY RULES). ♦ Place the vehicle on the center stand. ♦ Unscrew and remove the one screw (1). CAUTION Proceed with care. Do not damage the tabs and/or the slots in which they fit.

  • Page 27: Removing The Rear-View Mirrors

    Scarabeo 50 I.E.-50/100 4T REMOVING THE REAR-VIEW MIRRORS Carefully read p. 2 (GENERAL SAFETY RULES). The following information refers to one rear-view mirror only, but is valid for both. ♦ Place the vehicle on the center stand. ♦ Pull back the rubber boot (1) with your fingers. CAUTION Hold the rear-view mirror (2) carefully, so that it is not accidentally dropped.

  • Page 28: Removing The Rear Handlebar Cover

    Scarabeo 50 I.E.-50/100 4T REMOVING THE REAR HANDLEBAR COVER Carefully read p. 2 (GENERAL SAFETY RULES). ♦ Remove the front handlebar cover, see p. 26 (REMOV- ING THE FRONT HANDLEBAR COVER). ♦ Disconnect the two electric connectors of the direction indicators (1).

  • Page 29: Removing The Bumper

    Scarabeo 50 I.E.-50/100 4T REMOVING THE BUMPER Carefully read p. 2 (GENERAL SAFETY RULES). ♦ Remove the internal front shield and then remove the six clips (10) on each side. NOTE Upon reassembly, use new clips. REMOVING THE FRONT MUDGUARD Carefully read p.

  • Page 30: Removing The Saddle Support

    Scarabeo 50 I.E.-50/100 4T REMOVING THE SADDLE SUPPORT Carefully read p. 2 (GENERAL SAFETY RULES). ♦ Remove the rear part of the fairing, see p. 22 (RE- MOVING THE REAR PART OF THE FAIRING). ♦ Remove the battery as described on p. 75 (BATTERY STORAGE).

  • Page 31: Removing The Saddle Support 100

    Scarabeo 50 I.E.-50/100 4T REMOVING THE SADDLE SUPPORT Carefully read p. 2 (GENERAL SAFETY RULES). ♦ Remove the rear part of the fairing, see p. 22 (RE- MOVING THE REAR PART OF THE FAIRING). ♦ Remove the battery cover (1). ♦...

  • Page 32: Fuel Tank

    Scarabeo 50 I.E.-50/100 4T FUEL TANK Carefully read p. 2 (GENERAL SAFETY RULES). FUEL WARNING Gasoline is extremely flammable and in some condi- tions can become explosive. Therefore, it is neces- sary to refuel and carry out maintenance operations involving the fuel system in a well-ventilated area with the engine off.

  • Page 33: Draining The Fuel Tank

    Scarabeo 50 I.E.-50/100 4T DRAINING THE FUEL TANK Carefully read p. 31 (FUEL TANK). BE SURE TO KEEP THE DRAINED FUEL AWAY FROM CHILDREN. ♦ Place the vehicle on the center stand. ♦ Stop the engine and wait until it has cooled down. ♦...

  • Page 34: Draining The Fuel Tank 100

    Scarabeo 50 I.E.-50/100 4T DRAINING THE FUEL TANK Carefully read p. 31 (FUEL TANK). BE SURE TO KEEP THE DRAINED FUEL AWAY FROM CHILDREN. ♦ Place the vehicle on the center stand. ♦ Stop the engine and wait until it has cooled down. ♦...

  • Page 35: Removing Fuel Tank

    Scarabeo 50 I.E.-50/100 4T REMOVING FUEL TANK Carefully read p. 31 (FUEL TANK). ♦ Drain the fuel tank completely, see p. 32 (DRAINING THE FUEL TANK). ♦ Remove the fuel flange from the tank. ♦ Disconnect the electric connector of the fuel level gauge unit.

  • Page 36: Mixer Oil Tank

    Scarabeo 50 I.E.-50/100 4T MIXER OIL TANK Carefully read p. 2 (GENERAL SAFETY RULES). CAUTION Carefully wash your hands after handling the oil. Dispose of the oil properly. KEEP OIL AWAY FROM CHILDREN. WARNING If you should run the mixer oil tank dry, the engine will seize.

  • Page 37: Removal

    Scarabeo 50 I.E.-50/100 4T REMOVAL Carefully read p. 35 (MIXER OIL TANK) ♦ Remove the saddle support, see p. 29 (REMOVING THE SADDLE SUPPORT). ♦ Drain the 2 stroke oil tank (1) completely, see p. 35 (DRAINING). ♦ Disconnect the electric connector (2) of the mixer oil level gauge (3).

  • Page 38: Disassembling The Oil Pump

    Scarabeo 50 I.E.-50/100 4T DISASSEMBLING THE OIL PUMP ♦ Completely drain the mixer oil tank, as described on page 35 (DRAINING). ♦ Disconnect the electric connection (1). ♦ Remove the two clamps (2) and (3) from the piping. ♦ Remove the oil pump (4) after first unscrewing its support screw from the bottom.

  • Page 39: Bulbs

    Scarabeo 50 I.E.-50/100 4T BULBS Carefully read p. 2 (GENERAL SAFETY RULES). WARNING Risk of fire. Keep fuel and other flammable substances away from the electrical components. CAUTION Before changing a bulb, turn the ignition switch to position “ ” (OFF) (1) and wait a few seconds in order to allow the bulb to cool down.

  • Page 40: Changing The Headlight Bulbs

    Scarabeo 50 I.E.-50/100 4T CHANGING THE HEADLIGHT BULBS Carefully read p. 38 (BULBS). The headlight contains: – one low/hight beam bulb (1). To change the bulb: LOW/HIGH BEAM BULB ♦ Remove the front handlebar cover, see p. 26 (REMOV- ING THE FRONT HANDLEBAR COVER). ♦...

  • Page 41: Front And Rear Direction Indicators

    Scarabeo 50 I.E.-50/100 4T FRONT AND REAR DIRECTION INDICATORS CHANGING THE BULB Carefully read p. 38 (BULBS). NOTE Before changing a bulb, check the fuse. To change the bulb: ♦ Place the vehicle on the center stand. ♦ Unscrew and remove the screw (1). NOTE While removing the lens, use extra care to be sure that you do not break the key.

  • Page 42: Removing The Complete Direction Indicator

    Scarabeo 50 I.E.-50/100 4T REMOVING THE COMPLETE DIRECTION INDICATOR WARNING Risk of fire. Keep fuel and other flammable substances away from the electrical components. ♦ Place the vehicle on the center stand. ♦ Unscrew and remove the screw (1). NOTE While removing the lens, use extra care to be sure that you do not break the key.

  • Page 43: Rear Light

    Scarabeo 50 I.E.-50/100 4T REAR LIGHT CHANGING THE REAR LIGHT BULB Carefully read p. 38 (BULBS). ♦ Position the vehicle on the stand. ♦ Unscrew and remove the two screws (1). NOTE Take great care when removing the protective cover, so that you do not break the coupling tooth. ♦...

  • Page 44: Number Plate Lamp Bulb Changing Number Plate Lamp Bulb

    Scarabeo 50 I.E.-50/100 4T NUMBER PLATE LAMP BULB CHANGING NUMBER PLATE LAMP BULB Carefully read p. 38 (BULBS). To replace: ♦ Unfasten and remove the screw (1). ♦ Extract the rubber bulb holder (2). ♦ Remove the bulb from its housing. ♦...

  • Page 45: Dashboard 100

    Scarabeo 50 I.E.-50/100 4T DASHBOARD CHANGING THE DASHBOARD BULBS Carefully read p. 38 (BULBS). NOTE Before changing a bulb, check the fuses. The dashboard contains: – the warning light bulbs; – the dashboard lighting bulbs. To change the bulbs: ♦ Remove the front handlebar cover, see p. 26 (REMOV- ING THE FRONT HANDLEBAR COVER).

  • Page 46: Removing The Complete Dashboard

    Scarabeo 50 I.E.-50/100 4T REMOVING THE COMPLETE DASHBOARD WARNING Risk of fire. Keep fuel and other flammable substances away from the electrical components. ♦ Remove the front handlebar cover, see p. 26 (REMOV- ING THE FRONT HANDLEBAR COVER). ♦ Unscrew and remove the two screws (1). ♦...

  • Page 47: Brakes

    Scarabeo 50 I.E.-50/100 4T BRAKES WARNING Do not ride your vehicle with worn or malfunctioning brakes! The brakes are the most important safety sys- tem of your vehicle, and using the bike with brakes that are anything less than perfect is very likely to lead to a collision or upset, with consequent risk of serious injury or death.

  • Page 48: Disc Brakes

    Scarabeo 50 I.E.-50/100 4T DISC BRAKES Carefully read p. 2 (GENERAL SAFETY RULES) and p.46 (BRAKES). WARNING As mentioned above, the brakes are the most impor- tant safety system on your vehicle. For your safety, they must be in perfect repair, so they should be checked every time you ride your vehicle.

  • Page 49: Front And Rear Brake

    Scarabeo 50 I.E.-50/100 4T FRONT AND REAR BRAKE Carefully read p. 47 (DISC BRAKES). CHECKING THE SYSTEM NOTE Carry out these checks only on a firm, flat surface such as a concrete garage floor. ♦ Place the vehicle on the center stand. MIN = minimum level.
  • Page 50 Scarabeo 50 I.E.-50/100 4T TOPPING UP Carefully read p. 46 (BRAKES) and p. 47 (DISC BRAKES). ♦ Remove the front handlebar cover, see p. 26 (REMOV- ING THE FRONT HANDLEBAR COVER). CAUTION To remove the two screws (1) which hold the reservoir cover (2) in place, the handlebar must be rotated so that the fluid contained in the brake reservoir is parallel to the “MIN”...

  • Page 51: Brake Pads

    Scarabeo 50 I.E.-50/100 4T BRAKE PADS Carefully read p. 2 (GENERAL SAFETY RULES), and p.47 (DISC BRAKES). Check the brake pad wear after the first 500 km (312 mi) and then every 2,000 km (1,250 mi). The amount of wear that the brake pads experience depends on how the vehicle is used, how aggressively it is driven, and the condition of the roads upon which it is operated.

  • Page 52: Bleeding The Braking System

    Scarabeo 50 I.E.-50/100 4T BLEEDING THE BRAKING SYSTEM Carefully read p. 2 (GENERAL SAFETY RULES), and p.47 (DISC BRAKES). NOTE This vehicle is provided with front and rear disc brakes, with separate hydraulic system. The following information may refers to a single braking system, but is applicable for both braking system.

  • Page 53: Brake Calipers

    Scarabeo 50 I.E.-50/100 4T BRAKE CALIPERS Carefully read p. 2 (GENERAL SAFETY RULES), and p.47 (DISC BRAKES). REMOVING THE FRONT BRAKE CALIPER Carefully read above (BRAKE CALIPERS). WARNING A dirty disc soils the pads, with consequent reduction of the braking efficiency. Dirty pads must be replaced, while dirty discs must be cleaned with a high-quality degreaser.

  • Page 54: Removing The Rear Brake Shoes

    Scarabeo 50 I.E.-50/100 4T CAUTION Never apply the rear brake lever after removing the brake caliper. To do so will cause the caliper pistons to fall out of their seats in the caliper. This will cause brake fluid to spill from the caliper. ♦...

  • Page 55: Transmission

    Scarabeo 50 I.E.-50/100 4T TRANSMISSION CHECKING THE TRANSMISSION OIL LEVEL Carefully read p. 2 (GENERAL SAFETY RULES). DISPOSE OF OIL PROPERLY To control the transmission oil level, carry out the follow- ing operations every 3,000 km (2,500 mi) of use, or every 12 months: ♦...

  • Page 56: Wheels / Tires

    Scarabeo 50 I.E.-50/100 4T WHEELS / TIRES Carefully read p. 2 (GENERAL SAFETY RULES). INSPECTING THE WHEELS ♦ Make sure that the wheel rims are neither cracked, nor deformed. Change them if necessary. ♦ Check the wheel eccentricity. If it is deformed beyond the tolerance limits, check the rim and the bearings.
  • Page 57 Scarabeo 50 I.E.-50/100 4T WARNING Change, repair, maintenance and balancing operations are very important and should be carried out by quali- fied technicians with appropriate tools. If the tires are new, they may still be covered with a slippery film: drive carefully for the first miles. Never attempt to treat a tire with any kind of rubber dressing.

  • Page 58: Front Wheel

    Scarabeo 50 I.E.-50/100 4T FRONT WHEEL DISASSEMBLY Carefully read p. 2 (GENERAL SAFETY RULES). WARNING While disassembling and reassembling the wheel, pay extra care not to damage the brake lines, discs or pads. Before carrying out the following operations, let the engine and the exhaust silencer cool down until they reach room temperature, in order to avoid burns.

  • Page 59: Checking

    Scarabeo 50 I.E.-50/100 4T CHECKING ♦ Before reassembly, check the condition of the following parts, and if in any way damaged, replace them: – washer (6); – bearings (12); – speedometer drive (5); – spacer (13); – brake disc (14), [(minimum thickness 3.5 mm (0.138 in)]; –...
  • Page 60 Scarabeo 50 I.E.-50/100 4T ♦ Insert the wheel between the fork legs, carefully introducing the disc into the brake caliper. WARNING Danger of injury. Keep your fingers clear. Do not attempt to line up the wheel and the axle clamps with your fingers. Use work-gloves to carrying out these operations.

  • Page 61: Rear Wheel

    Scarabeo 50 I.E.-50/100 4T REAR WHEEL DISASSEMBLY Carefully read p. 2 (GENERAL SAFETY RULES). WARNING A dirty disc soils the pads, with consequent reduction of the braking efficiency. Dirty pads must be replaced, while dirty discs must be cleaned with a high-quality degreaser.

  • Page 62: Checking The Engine Fulcrum Axis

    ♦ If any play is detected, check all of the fasteners attaching the mounting unit, see p. 73 (ENGINE MOUNTING BUSHINGS). ♦ If play can still be deteched, contact your Local aprilia Dealer for repair instructions. IGNITION SWITCH / STEERING LOCK REMOVAL ♦...

  • Page 63: Air Cleaner

    Scarabeo 50 I.E.-50/100 4T AIR CLEANER Carefully read p. 2 (GENERAL SAFETY RULES). WARNING The state of the air filter should be checked monthly or every 4,000 km (2,500 mi), depending on the conditions in which the vehicle is used. If it is used on dusty or wet roads, cleaning and replacement operations must be carried out more frequently.
  • Page 64 Scarabeo 50 I.E.-50/100 4T ♦ Remove the two screws (4) sideways. ♦ Remove the two screws (5) that fix the guard (6) to the engine. ♦ Unscrew the screw (7) and lift the rear shock absorber. ♦ Unscrew the two screws (8) and (9) from the flywheel side.

  • Page 65: Air Cleaner 100

    Scarabeo 50 I.E.-50/100 4T AIR CLEANER Carefully read p. 2 (GENERAL SAFETY RULES). WARNING Clean and check of the air filter should be checked monthly or every 3,000 Km (1,875 mi), depending on the conditions in which the vehicle is used. If it is used on dusty or wet roads, cleaning and replacement operations must be carried out more frequently.

  • Page 66: Removing The Complete Air Cleaner Casing

    Scarabeo 50 I.E.-50/100 4T REMOVING THE COMPLETE AIR CLEANER CASING Carefully read p. 2 (GENERAL SAFETY RULES). ♦ Place the vehicle on the center stand. ♦ Unloose and remove the two screws (1) keeping the relative stop nust situated on the back. ♦...

  • Page 67: Fork Head

    Scarabeo 50 I.E.-50/100 4T FORK HEAD CHECKING THE BEARING PLAY Carefully read p. 2 (GENERAL SAFETY RULES). To check the steering it is necessary to: ♦ Place the vehicle on the center stand. NOTE Prepare a 200 mm (7.87 in) high support, the base of which must measure 200 x 200 mm (7.87 x 7.87 in).

  • Page 68: Removing The Fork Head Bearings

    Scarabeo 50 I.E.-50/100 4T REMOVING THE FORK HEAD BEARINGS Carefully read p. 2 (GENERAL SAFETY RULES). WARNING Put a proper support under the vehicle, in order to prevent it from falling down. ♦ Place the vehicle on the center stand, on a lifting platform, with the front wheel protruding from the platform edge.

  • Page 69: Front Fork

    Scarabeo 50 I.E.-50/100 4T FRONT FORK REMOVING THE COMPLETE FORK To remove the complete fork, along with front wheel and front mudguard mounted, follow the instructions of p. 67 (REMOVING THE FORK HEAD BEARINGS). In case of removing for remplacement of the complete fork, keep to the instructions of p.

  • Page 70: Rear Suspension

    Scarabeo 50 I.E.-50/100 4T REAR SUSPENSION REMOVAL Carefully read p. 2 (GENERAL SAFETY RULES). ♦ Place the vehicle on the center stand. CAUTION Put a proper spacer (X) under the rear wheel to prevent it from falling and pushing the air cleaner casing into the frame.

  • Page 71: Engine

    Scarabeo 50 I.E.-50/100 4T CAUTION If the additional flange (4) is provided, do not unscrew the screws (5) and (6), but follow the procedure described here. ♦ Unscrew and remove the screws (7) and (8). Screw (7) and (8) tightening torque: 12Nm (8.68 ftlb).
  • Page 72 Scarabeo 50 I.E.-50/100 4T ♦ Remove the connectors (7) of the throttle positioning sensor (8), temperature sensor (9) and air injector ♦ Remove the screw (10) that fastens the ground cable to the engine. ♦ Remove the fuel pipe (5) Release 00 2003-02...
  • Page 73 Scarabeo 50 I.E.-50/100 4T ♦ Remove the rear brake caliper, see p. 52 (REMOVING THE REAR BRAKE CALIPER) ♦ Fix the brake caliper to the vehicle frame ♦ Unscrew and remove the screw (11) and free the brake pipe from the cable gland (12) ♦...

  • Page 74: Engine Mounting Bushings

    Scarabeo 50 I.E.-50/100 4T ENGINE MOUNTING BUSHINGS REMOVAL Carefully read p. 2 (GENERAL SAFETY RULES). Worn out or damaged bonded rubber engine mounting bushings can cause annoying vibration and unsafe vehicle handling. To check the condition of the bushings, it is necessary to remove the engine mounting shaft (see figure below).

  • Page 75: Battery

    Scarabeo 50 I.E.-50/100 4T BATTERY Carefully read p. 2 (GENERAL SAFETY RULES). Check the electrolyte level and the tightness of the terminals after the first 500 km (312 mi) and successively every 4,000 km (2,500 mi) or 8 months. WARNING Batteries, when charged, give off hydrogen gas, which is highly explosive.

  • Page 76: Checking And Cleaning The Terminals And Clamps

    Scarabeo 50 I.E.-50/100 4T If your battery is equipped with an overflow tube, always ensure that it is properly installed, and properly routed. Failure to adhere to this instruction can cause corrosive fumes from the battery to cause serious damage to your vehicle.

  • Page 77: Recharging The Battery

    Scarabeo 50 I.E.-50/100 4T RECHARGING THE BATTERY Carefully read p. 74 (BATTERY). WARNING The vehicle comes supplied with a maintenance-free sealed battery, therefore the liquid level must not be checked. This battery is completely sealed. Do not attempt to remove the caps. There is never any need to add water to this battery.

  • Page 78: Installing The Battery

    If a fuse blows frequently, there probably is a short circuit or an overload in the electrical system. If this occurs, take the vehicle to your Local aprilia Dealer. If an electric component does not work or works irregu- larly, or if the vehicle fails to start, it is necessary to check the fuse (1).
  • Page 79 If you replace the fuse and it blows again immedi- ately, there is a serious problem with the electrical system of your vehicle. Do not attempt to continue using your vehicle. Take it to your Local aprilia Dealer for repair and service. NOTE If you use the spare fuse (4), replace it as soon as convenient.

  • Page 80: Electrical System

    Scarabeo 50 I.E.-50/100 4T ELECTRICAL SYSTEM CONTENTS Recharge and general power supply circuit ....80 Recharge and general power supply circuit ..81 Injection power ............82 Injection diagram ............83 Stoplight circuit and starter circuit ........87 Direction indicator circuit and horn circuit ....

  • Page 81: Recharge And General Power Supply Circuit

    Scarabeo 50 I.E.-50/100 4T RECHARGE AND GENERAL POWER SUPPLY CIRCUIT WIRING DIAGRAM INJECTION RELAY 7,5 A ELECTRICAL FUNCTIONS UNDER D.C. Ar/Bi LIGHTS INJECTION 10 A Arrangement of the components: see p. 96 - 97. battery and fuse. 13) Fuses – Check the battery (see below). 14) Battery –...

  • Page 82: Recharge And General Power Supply Circuit

    Scarabeo 50 I.E.-50/100 4T RECHARGE AND GENERAL POWER SUPPLY CIRCUIT WIRING DIAGRAM 5 4 3 2 1 Arrangement of the components: see p. 98-99-100-101 battery and fuse. 1) Generator – Check the battery (see below). 5) Voltage regulator – Check the generator (see below). Battery –...

  • Page 83: Injection Power

    Scarabeo 50 I.E.-50/100 4T INJECTION POWER WIRING DIAGRAM INJECTION (CHECK) INJECTION (POWER) 10 A Arrangement of the components: see p. 96-97 13) Fuses 14) Battery 17) Injection relay 29) Key switch TROUBLESHOOTING – Check the condition of the 10A fuse. –...

  • Page 84: Injection Diagram

    Scarabeo 50 I.E.-50/100 4T INJECTION DIAGRAM WIRING DIAGRAM FROM INJECTION RELAY Bi/Vi Bi/R Bl/G Bi/G Ar/N 7.5A FUSE Arrangement of the components: see p. 96-97 2) CDI 3) Serial connection 4) Throttle sensor 5) Pick-up 6) Temperature sensor 7) Oil pump 8) Fuel injector 9) Air injector 10) Fuel pump...
  • Page 85 Scarabeo 50 I.E.-50/100 4T TROUBLESHOOTING – Check the efficiency of the spark plug cap. – Using an ohmmeter-tester, check the coil primary and secondary values: between the two terminals for the connector 0.7 kΩ ± 20% between the HT cable and the coil casing 7.1 kΩ ± 20% NOTE Before taking this reading, disconnect the spark plug cap.
  • Page 86 Scarabeo 50 I.E.-50/100 4T CHECKING THE PICK-UP – Using an ohmmeter-tester, check the resistance values between the two terminals from the pick-up side. Correct value: 385 Ω ± 20% CHECKING THE FUEL PUMP – Energize the pump (12VDC), taking care to respect polarity, and check that the resulting fuel flow is sufficient.
  • Page 87 Scarabeo 50 I.E.-50/100 4T – With throttle CLOSED. Ω Ω 1.75 kΩ 1 kΩ Ω Ω 1.75 kΩ 1 kΩ – With throttle OPEN. Ω Ω 1 kΩ 1.75 kΩ Ω Ω 1 kΩ 1.75 kΩ CHECKING THE ATMOSPHERIC PRESSURE SENSOR –...

  • Page 88: Stoplight Circuit And Starter Circuit

    Scarabeo 50 I.E.-50/100 4T STOPLIGHT CIRCUIT AND STARTER CIRCUIT WIRING DIAGRAM POSITIVE UNDER KEY Arrangement of the components: see p. 96-97 – Check the front stoplight switch (see below). 14) Battery – Check the rear stoplight switch (see below). 15) Start relay 16) Starter motor 21) Front brake stoplight switch TEST DATA...
  • Page 89 Scarabeo 50 I.E.-50/100 4T CHECKING THE START RELAY To check the efficiency of the relay switch: – Energize (12 V) the two male terminals (85 - 86). – Using an ohmmeter-tester, check the continuity be- tween the other two terminals (87 - 30). Correct value with relay energized: 0 Ω...

  • Page 90: Direction Indicator Circuit And Horn Circuit

    Scarabeo 50 I.E.-50/100 4T DIRECTION INDICATOR CIRCUIT AND HORN CIRCUIT WIRING DIAGRAM POSITIVE UNDER KEY Arrangement of the components: see p. 96-97 23) Rear left direction indicator 25) Rear right direction indicator 30) Flasher 31) Horn push button 32) Horn 36) Direction indicator warning light 41) Front left direction indicator 43) Front right direction indicator...

  • Page 91: Direction Indicator Circuit And Horn Circuit

    Scarabeo 50 I.E.-50/100 4T DIRECTION INDICATOR CIRCUIT AND HORN CIRCUIT WIRING DIAGRAM 3 4 5 POSITIVE UNDER KEY Arrangement of the components: see p. 98-99-100-101 5) Voltage regulator 14) Rear right direction indicator 16) Rear left direction indicator 18) Left dimmer switch 31) Front right direction indicator 32) Front left direction indicator 35) Horn...

  • Page 92: Lighting Circuit

    Scarabeo 50 I.E.-50/100 4T LIGHTING CIRCUIT WIRING DIAGRAM GENERATOR TO THE KEY SWITCH AND FUSE AND INJECTION RELAY Arrangement of the components: see p. 96 - 97 18) Voltage regulator 24) Rear parking light/stoplight bulb 31) Left dimmer switch 37) High beam warning light 38) Dashboard light 42) High/low beam bulb 44) License plate lamp...

  • Page 93: Lighting Circuit 100

    Scarabeo 50 I.E.-50/100 4T LIGHTING CIRCUIT WIRING DIAGRAM LOCK LOCK Arrangement of the components: see p. 98-99-100-101 – Check the generator. 5) Voltage regulator C. BULBS CUT OUT FREQUENTLY 6) Battery – Make sure that the lights do not vibrate excessively 12) License plate lamp and do not get in contact with the parts of the vehicle 15) Rear parking light/stoplight bulb...

  • Page 94: Dashboard Lights Circuit

    Scarabeo 50 I.E.-50/100 4T DASHBOARD LIGHT CIRCUIT WIRING DIAGRAM POSITIVE UNDER KEY STARTER BUTTON Arrangement of the components: see p. 96-97 Oil level switch 27) Control diode 33) Fuel level sensor 35) Fuel level device 39) Mixer oil level warning light Release 00 2003-02...
  • Page 95 Scarabeo 50 I.E.-50/100 4T FUEL LEVEL INDICATOR TROUBLESHOOTING A. INSTRUMENT ALWAYS INDICATES O EVEN WITH FULL TANK – Make sure that there is voltage between the green/red and the blue cable of the instrument. – Check the cable connections. – Make sure that the gray/green cable isn’t open be- tween the instrument and the sensor.
  • Page 96 Scarabeo 50 I.E.-50/100 4T 2 STROKE OIL RESERVE WARNING LIGHT The 2 stroke oil reserve warning light comes on every time the engine is started, to make sure that the bulb functions correctly. TROUBLESHOOTING A. WARNING LIGHT DOESN’T COME ON WHEN OIL LEVEL IS INSUFFICIENT –...

  • Page 97: Wiring Diagrams - Scarabeo

    Scarabeo 50 I.E.-50/100 4T WIRING DIAGRAM - SCARABEO 50 Release 00 2003-02...
  • Page 98 Scarabeo 50 I.E.-50/100 4T CABLE COLOURS Wiring diagram key 1) Multiple connectors orange 2) CDI Az light blue 3) Serial connection blue 4) Throttle sensor white 5) Pick-up yellow 6) Temperature sensor gray 7) Oil pump brown 8) Fuel injector black 9) Air injector 10) Fuel pump...

  • Page 99: Wiring Diagrams - Scarabeo

    Scarabeo 50 I.E.-50/100 4T WIRING DIAGRAM - SCARABEO Release 00 2003-02...
  • Page 100 Scarabeo 50 I.E.-50/100 4T CABLE COLOURS Wiring diagram key 1) Generator orange 2) Transducer Az light blue 3) Spark plug blue 5) Voltage regulator white 6) Battery yellow 7) Starter motor gray 8) Start relay brown 9) Front stoplight switch black 10) Rear stoplight switch 13) Fuel level sensor...

  • Page 101: Wiring Diagrams - Scarabeo

    Scarabeo 50 I.E.-50/100 4T WIRING DIAGRAM - SCARABEO Release 00 2003-02...
  • Page 102 Scarabeo 50 I.E.-50/100 4T CABLE COLOURS Wiring diagram key 1) Generator orange 2) Transducer Az light blue 3) Spark plug blue 5) Voltage regulator white 6) Battery yellow 7) Starter motor gray 8) Start relay brown 9) Front stoplight switch black 10) Rear stoplight switch 12) License plate lamp...

  • Page 103: Arrangement Of The Components

    Scarabeo 50 I.E.-50/100 4T ARRANGEMENT OF THE COMPONENTS 3) Serial connection 12) Spark plug 13) Fuses 14) Battery 17) Injection relay 18) Voltage regulator 20) Pressure sensor (not fitted as standard) 22) Rear brake stoplight switch 23) Rear left direction indicator 24) Rear parking/brake lamp 26) Oil level switch 31) Left dimmer switch...
  • Page 104 Scarabeo 50 I.E.-50/100 4T 2) C.D.I. 4) Throttle sensor 5) Pick-up 7) Oil pump 8) Fuel injector 9) Air injector 10) Fuel pump 11) H.T. coil 15) Start relay 16) Starter motor 19) Generator 21) Front brake stoplight switch 25) Rear right direction indicator 27) Control diode 28) Right dimmer switch 29) Key switch...

  • Page 105: Arrangement And Fastening Of Cables And Wiring

    Scarabeo 50 I.E.-50/100 4T ARRANGEMENT AND FASTENING OF CABLES AND WIRINGS ARRANGEMENT OF CABLES AND WIRINGS Release 00 2003-02...
  • Page 106 Scarabeo 50 I.E.-50/100 4T 1) Multiple connectors 2) C.D.I. 4) Throttle sensor 5) Pick-up 6) Temperature sensor 7) Oil pump 9) Air injector 10) Fuel pump 11) HT coil 13) Fuses 14) Battery 15) Start relay 16) Starter motor 17) Injection relay 18) Voltage regulator 20) Pressure sensor (not fitted as standard) 21) Front brake stoplight switch...
  • Page 107 Scarabeo 50 I.E.-50/100 4T FASTENING OF CABLES AND WIRINGS P Q R S T F G H I L M N Release 00 2003-02...
  • Page 108 Scarabeo 50 I.E.-50/100 4T Release 00 2003-02...
  • Page 109 Scarabeo 50 I.E.-50/100 4T NOTES Release 00 2003-02...
  • Page 110 G.Galilei, 1 30033 Noale (VE) Italy tel. +39 041.5829111 fax +39 041.5829190 www.serviceaprilia.com...

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