APRILIA SCARABEO 500 - 2008 Leitfaden

SERVICE STATION MANUAL

854190

SCARABEO 500

SERVICE STATION

MANUAL

SCARABEO 500

The descriptions and illustrations given in this publication are not binding; While the basic characteristics

as described and illustrated in this manual remain unchanged, aprilia reserves the right, at any time and

without being required to update this publication beforehand, to make any 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 publication are available in all countries. The availability of individual models

should be confirmed with the official aprilia sales network.

prohibited. aprilia - After-sales service.

aprilia trademark is property of Piaggio & C. S.p.A.

SERVICE STATION MANUAL

SCARABEO 500

NOTE Provides key information to make the procedure easier to understand and carry out.

CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.

WARNING Refers to specific procedures to carry out 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 this symbol indicate the correct use of the vehicle

to prevent damaging the environment.

Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious

damage to the vehicle and sometimes even the invalidity of the guarantee.

INDEX OF TOPICS

CHARACTERISTICS 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 CHAS

PRE-DELIVERY PRE DE

INDEX OF TOPICS

CHARACTERISTICS CHAR

Rules

Safety rules

GENERAL PRECAUTIONS AND INFORMATION

When repairing, dismantling and reassembling the vehicle, follow the recommendations given below

carefully.

CAUTION

USE OF NAKED FLAMES IS FORBIDDEN DURING ALL TYPES OF OPERATION. BEFORE START-

ING ANY MAINTENANCE OPERATION OR INSPECTION ON THE VEHICLE, SWITCH OFF THE

ENGINE AND REMOVE THE KEY. WAIT UNTIL THE ENGINE AND THE EXHAUST SYSTEM ARE

COLD, IF POSSIBLE, RAISE THE VEHICLE USING A SUITABLE TOOL ON FIRM AND LEVEL

GROUND. TO AVOID BURNS PAY SPECIAL CARE WITH HOT ENGINE AND EXHAUST SYSTEM

PARTS.

DO NOT HOLD ANY MECHANICAL OR OTHER SCOOTER PARTS WITH YOUR MOUTH: SCOOT-

ER COMPONENT ARE NOT EDIBLE, ON THE CONTRARY SOME OF THEM ARE HARMFUL AND

EVEN TOXIC.

CARBON MONOXIDE

If you need to keep 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 enclosed area, make sure to use a smoke-extraction system.

CAUTION

EXHAUST EMISSIONS CONTAIN CARBON MONOXIDE, A POISONOUS GAS WHICH CAN CAUSE

LOSS OF CONSCIOUSNESS AND EVEN DEATH.

FUEL

CAUTION

FUEL USED TO DRIVE EXPLOSION ENGINES IS HIGHLY FLAMMABLE AND CAN BECOME EX-

PLOSIVE UNDER SPECIFIC CONDITIONS.

IT IS THEREFORE RECOMMENDED TO CARRY OUT REFUELLING AND MAINTENANCE PRO-

CEDURES IN A VENTILATED AREA WITH THE ENGINE SWITCHED OFF.

DO NOT SMOKE DURING REFUELLING AND NEAR FUEL VAPOURS, AVOIDING ANY CONTACT

WITH NAKED FLAMES, SPARKS OR OTHER SOURCES WHICH MAY CAUSE THEM TO IGNITE

OR EXPLODE.

CAUTION

DO NOT DISPOSE OF FUEL INTO THE ENVIRONMENT.

CAUTION

KEEP OUT OF THE REACH OF CHILDREN

HIGH-TEMPERATURE COMPONENTS

SCARABEO 500 Characteristics

CHAR - 7

The engine and the components of the exhaust system can get very hot and remain hot for some time

even after the engine has been switched off.

Before handling these components, make sure that you are wearing insulating gloves or wait until the

engine and the exhaust system have cooled down.

TRANSMISSION OIL AND USED FORK OIL

CAUTION

IT IS ADVISABLE TO WEAR LATEX GLOVES WHEN CARRYING OUT SERVICE WORK.

THE TRANSMISSION OIL MAY CAUSE SKIN DAMAGE IF HANDLED FREQUENTLY AND FOR

LONG PERIODS.

WASH YOUR HANDS CAREFULLY AFTER HANDLING OIL.

HAND THE OIL OVER TO OR HAVE IT COLLECTED BY THE NEAREST USED OIL RECYCLING

COMPANY OR THE SUPPLIER.

IT IS ADVISABLE TO WEAR LATEX GLOVES WHEN CARRYING OUT SERVICE WORK.

CAUTION

DO NOT DISPOSE OF OIL INTO THE ENVIRONMENT.

CAUTION

KEEP OUT OF THE REACH OF 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 SERVICING THE BRAKE SYSTEM.

THE BRAKE FLUID IS EXTREMELY DANGEROUS TO THE EYES.

IN THE EVENT OF ACCIDENTAL CONTACT WITH THE EYES, RINSE THEM IMMEDIATELY WITH

ABUNDANT COLD, CLEAN WATER AND SEEK MEDICAL ADVICE.

CAUTION

KEEP OUT OF THE REACH OF CHILDREN

HYDROGEN GAS AND BATTERY ELECTROLYTE

CAUTION

THE BATTERY ELECTROLYTE IS TOXIC, CORROSIVE AND AS IT CONTAINS SULPHURIC ACID,

IT CAN CAUSE BURNS WHEN IN CONTACT WITH THE SKIN.

WHEN HANDLING THE BATTERY ELECTROLYTE, WEAR TIGHT-FITTING GLOVES AND PRO-

TECTIVE APPAREL.

IF THE ELECTROLYTIC FLUID GETS INTO CONTACT WITH THE SKIN, WASH WITH ABUNDANT

COOL WATER.

IT IS PARTICULARLY IMPORTANT TO PROTECT THE EYES BECAUSE EVEN TINY AMOUNTS

OF BATTERY ACID MAY CAUSE BLINDNESS. IF IT COMES INTO CONTACT WITH THE EYES,

Characteristics SCARABEO 500

CHAR - 8

RINSE THEM CAREFULLY WITH WATER FOR FIFTEEN MINUTES, THEN SEE AN EYE SPECIAL-

IST AS SOON AS POSSIBLE.

IF IT IS ACCIDENTALLY SWALLOWED, DRINK LARGE QUANTITIES OF WATER OR MILK, FOL-

LOWED BY MILK OF MAGNESIA OR VEGETAL OIL, AND SEEK MEDICAL ADVICE IMMEDIATE-

LY.

THE BATTERY RELEASES EXPLOSIVE GASES. KEEP IT AWAY OF FLAMES, SPARKS, CIGA-

RETTES OR ANY OTHER HEAT SOURCE.

ENSURE ADEQUATE VENTILATION WHEN SERVICING OR RECHARGING THE BATTERY.

CAUTION

KEEP OUT OF THE REACH OF CHILDREN

CAUTION

THE BATTERY LIQUID IS CORROSIVE.

DO NOT POUR OR SPILL IT, PARTICULARLY ON PLASTIC COMPONENTS.

ENSURE THAT THE ELECTROLYTIC ACID IS COMPATIBLE WITH THE BATTERY TO BE ACTI-

VATED.

Maintenance rules

GENERAL PRECAUTIONS AND INFORMATION

When repairing, dismantling and reassembling the vehicle, follow the recommendations given below

carefully.

CAUTION

UNLESS OTHERWISE INDICATED, REFIT THE UNIT FOLLOWING THE REMOVAL STEPS BUT

IN REVERSE ORDER. THE 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.

NEVER USE FUEL AS SOLVENT FOR CLEANING THE SCOOTER.

DO NOT USE ALCOHOL, PETROL OR SOLVENTS TO CLEAN RUBBER AND PLASTIC PARTS

AND THE SADDLE. USE ONLY WATER AND NEUTRAL SOAP INSTEAD.

DISCONNECT THE NEGATIVE CABLE (-) OF THE BATTERY IF YOU INTEND TO CARRY OUT

ELECTRICAL WELDING WORK.

BEFORE REMOVING COMPONENTS

•Before dismantling components, remove dirt, mud, dust and foreign bodies from the vehicle.

•Use the specific tools designed for this scooter, as required.

REMOVAL OF COMPONENTS

•Do not loosen and/or tighten screws and nuts using pliers or other tools than the specially

designed wrench.

•Mark positions on all connection joints (pipes, cables etc.) before separating them, and

identify them with distinctive symbols.

•Each component needs to be clearly marked in order to be identified during reassembly.

•Clean and wash the dismantled components carefully using a low-flammability detergent.

SCARABEO 500 Characteristics

CHAR - 9

•Keep coupled parts together since they have "adjusted" to each other due to normal wear

and tear.

•Some components must be used together or replaced altogether.

•Keep away from heat sources.

REASSEMBLING COMPONENTS

CAUTION

NEVER REUSE A CIRCLIP; IF A CIRCLIP HAS BEEN REMOVED, IT MUST BE REPLACED WITH

A NEW ONE. WHEN INSTALLING A CIRCLIP, ENSURE THAT ITS ENDS ARE NOT STRETCHED

MORE THAN IS NECESSARY TO FIT IT ONTO THE SHAFT.

AFTER INSTALLING THE CIRCLIP, CHECK THAT IT IS FULLY AND CLEANLY INSTALLED IN ITS

SEAT.

DO NOT USED COMPRESSED AIR TO CLEAN BEARINGS.

NOTE

BEARINGS MUST BE ABLE TO ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE, OTH-

ERWISE THEY NEED REPLACING.

•Use only ORIGINAL aprilia SPARE PARTS.

•Comply with lubricant and consumables usage guidelines.

•Lubricate parts (whenever possible) before reassembling them.

•When tightening nuts and screws, start from the ones with the largest section or from the

internal ones, moving diagonally. Tighten 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 is damaged.

•When fitting bearings, make sure to lubricate them well.

•Check that each component is fitted correctly.

•After a repair or routine maintenance procedure, carry out pre-ride checks and test the ve-

hicle on private grounds or in an area with low traffic density.

•Clean all junction surfaces, oil guard rims and washers before refitting them. Smear a light

layer of lithium-based grease on the oil guard rims. Reassemble the oil guards and the

bearings with the brand or lot number facing outward (visible side).

ELECTRIC CONNECTORS

Electric connectors must be disconnected as described below as non-compliance with the procedure

so described causes irreparable damage to both the connector and the cable harness: Press the rele-

vant safety hooks, if any.

CAUTION

TO DISCONNECT THE TWO CONNECTORS, DO NOT PULL THE CABLES.

•Grip the two connectors and disconnect them by pulling them in opposite directions.

Characteristics SCARABEO 500

CHAR - 10

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