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SERVICE STATION MANUAL

1. Unscrew the clamp 1 Remove the pipe 2 Slide off the petrol flange 3 Unscrew the filter 4 from the flange 93 NOTE BLOW THE FILTER WITH COMPRESSED AIR AND REFIT Transmissions Check that the throttle grip works correctly CAUTION DO NOT USE THE VEHICLE IF THE THROTTLE GRIP CABLE IS DAMAGED TWISTED OR COILED THIS MAY INTERFERE WITH THE THROTTLE GRIP NORMAL OPERATION THE THROTTLE GRIP MAY GET LOCKED AND THIS MAY RESULT IN LOSS OF VEHICLE CON TROL Make sure the front fork rotation does not press the throttle grip and engage gears Furthermore make sure that the throttle grip goes back to idle position smoothly and automatically when released If this does not occur NOTE USED THE SPECIFIC LUBRICANT AVAILABLE IN THE MARKET TO LUBRICATE THE COMPO NENTS MAIN 47 Maintenance SCARABEO 50 4T 4V Check the position and lubrication of the following components e throttle grip cable sheath e throttle grip regulator 18 cable terminals throttle grip Check the throttle grip adjustment Throttle grip adjustment NOTE BEFORE CARRYING OUT ANY TYPE OF OPERATIONS MAKE SURE THE THROTTLE GRIP WORKS PROPERLY The throttle grip cable backslash must be between 0 08 m 7 2 3mm 0 08 0 12 in measured at the throttle 0 12 In trim see the drawing above To adjust the cable Park the vehicle on its centre stand Pull the rubber sheathing 1
2. NOTE OBSERVE THE SPEEDOMETER TRANSMISSION POSI TION 5 AND THE WASHER POSITION 6 INORDER TO REFIT THEM CORRECTLY Loosen axle 4 completely with the adequate spanner Hold the front wheel and remove axle 4 manually e Hemove the washer 6 CAUTION NEVER TOUCH THE FRONT BRAKE LEVER ONCE THE FRONT WHEEL IS REMOVED DOING SO MAY CAUSE THE CALLIPER PISTONS TO COME OUT AND THE BRAKE FLUID TO SEEP THROUGH Completely remove the wheel pulling it forwards Disconnect the speedometer transmission 5 SUSP 142 SCARABEO 50 4T 4V Front wheel hub overhaul Remove the front wheel Clean the two sides of the hub with a cloth With the specific extractor take out the two bearings e Collect the internal spacer Carry out a thorough check of the bear ings Clean the inside of the hub thoroughly Wash all the parts with detergent BEARINGS Manually rotate the internal ring 1 which must turn smoothly without obstacles and or noise There must be no axial clearance The bearings presenting these problems must be replaced CAUTION CHECK THAT ALL THE PARTS ARE IN GOOD CONDI TIONS SPECIALLY THE ONES BELOW GASKETS Suspensions Check that the gaskets are in good conditions replace them if they show signs of damage or excessive wear wheel spindle Using a dial gauge check the wheel pin 2 ec centricity Replace the pin 2 if the eccentrici
3. Check that the diaphragm closing line and the float central line are parallel as shown in the figure Blow air into the float chamber and fit it as well as the corresponding gasket on the carburettor body with the 3 fixing screws NOTE ALWAYS USE NEW RINGS AND GASKETS FOR REFIT TING WARNING THE SCREW IN THE FLOAT CHAMBER BOTTOM IS A BLEED SCREW AND CONSEQUENTLY IT ONLY RE QUIRES CLEANING ENG 136 SCARABEO 50 4T 4V Engine Fit the diaphragm into the throttle valve Fit the tapered pin together with the plastic sup port and the contrast spring into the throttle valve NOTE PLACE THE SPRING PLASTIC SUPPORT WITH ITS TEETH FACING THE INNER SIDE OF THE DIAPHRAGM TO BE ABLE TO FIT THE LOWER END OF THE THROTTLE VALVE SPRING Fit the vacuum chamber cover with the 2 fixing screws paying special attention to the spring Inspecting the automatic choke device Check that the automatic starter piston is not dis torted or rusty Check that the piston slides freely in its seat Check that the piston sealing O Ring is not de formed The starter must be more or less functional de pending on the ambient temperature Measure the piston protrusion as shown in the figure and check the corresponding value Make sure that the starter is adjusted for the am bient temperature Characteristic protrusion value 11 5 mm ambient temperature 24 C ENG 137 Engine SCARA
4. Loosen and remove the lower screw 11 of the rear shock absorber with the washer Turn the shock absorber and fix it to the chassis CAUTION SUPPORT THE SCOOTER FIRMLY Unscrew and remove the engine pivot link rod nut 12 and the correspond ing washer CAUTION BEFORE REMOVING THE ENGINE FULCRUM LINK ROD PIN SUPPORT THE SCOOTER ADEQUATELY TO PRE VENT IT FROM FALLING Operating on the chassis lift the vehicle rear part SCARABEO 50 4T 4V Slide off the engine pivot link rod nut with the relevant washer completely Slide off the engine towards the back ENG VE 82 INDEX OF TOPICS Engine SCARABEO 50 4T 4V Automatic transmission Transmission cover Remove the 12 fixing screws Remove the oil filler plug and slide off the cover If this operation is carried out directly on the scoot er remove the transmission cooling sleeve and the air filter housing clamps NOTE TO REMOVE THE COVER USE A MALLET ON THE AP PROPRIATE SUPPLEMENTS Kickstart To remove the start up pinion push the starter lever to facilitate extracting the pinion Remove the kick starter screw and lever Remove the Seeger ring and the washer indica ted in the figure Slide off the toothed sector WARNING THE SECTION KEEPS THE SPRING SET BE CAREFUL SO AS NOT TO CAUSE ANY ACCIDENTS Air duct To remove the intake throat on the transmission cover just remove the three fixi
5. SCARABEO 50 4T 4V Description Tool to fit the start up sector spring 17 mm guide Tool to fit remove the pin Tool for fitting the pin snap rings Support to check piston position Tool for fitting removing the camshaft Driving pulley lock wrench Pipe to remove and refit the driven pulley shaft SCARABEO 50 4T 4V Stores code 020456Y 020565Y 020683Y 020680Y Description 024 mm adaptor Flywheel lock calliper spanner Valve pressing member TXB Navigator Tooling TOOL 37 INDEX OF TOPICS SCARABEO 50 4T 4V Maintenance Maintenance chart ROUTINE MAINTENANCE TABLE I INSPECT AND CLEAN ADJUST LUBRICATE OR REPLACE IF NECESSARY C CLEAN R REPLACE A ADJUST L LUBRICATE Check level every 3 000 km Replace every 2 years Replace every 4 years km x 1 000 1 6 42 Safety locks Driving belt Spark plug Throttle control A Oil mesh filter C SAS filter Air filter Solenoid filter C Valve clearance Electrical system and battery Cooling system Brake fluid Brake control levers Headlight aiming adjustment Engine oil Hub oil Vehicle road test Tyre pressure and wear Sliding blocks Variable speed rollers Brake pads Odometer gear Idle speed A Suspension Steering A Transmissions Fuel pipes 18 30 54 O O O O m 2 ro O ol gt d D X oO m ls O gt DI DI 1 lOlOlOjOo I8 O IOJO O
6. FACE SUCH AS A GARAGE CONCRETE FLOOR Park the vehicle on its centre stand MIN minimum level Turn the handlebar so that the fluid in side the brake reservoir reaches the MIN level reference mark stamped on the sight glass 3 MAIN 49 Maintenance SCARABEO 50 4T 4V e Make sure that the fluid level in the res ervoir is above the MIN reference mark stamped on the sight glass 3 Top up e Remove the front handlebar cover CAUTION TO REMOVE THE TWO SCREWS 1 FIXING THE RESER VOIR COVER 2 TURN THE HANDLEBAR SO THAT THE FLUID INSIDE THE BRAKE FLUID RESERVOIR IS AT THE MIN LEVEL REFERENCE MARK STAMPED ON THE SIGHT GLASS 3 IF THIS PROCEDURE IS NOT CARRIED OUT THE BRAKE FLUID WILL SPILL OUT OF THE RES ERVOIR e Turn the handlebar so that the fluid inside the reservoir reaches the MIN level reference mark stamped on the sight glass 3 CAUTION DO NOT OPERATE THE REAR BRAKE LEVER NOR TURN THE HANDLEBAR AFTER THE SCREWS 1 OR THE COVER 2 HAVE BEEN REMOVED THIS WOULD CAUSE BRAKE FLUID TO SPLASH OR SPILL e Undo the two screws 1 e Remove cover 2 Remove cover guide 4 WARNING AVOID PROLONGED AIR EXPOSURE OF THE BRAKE FLUID BRAKE FLUID IS HYGROSCOPIC AND ABSORBS MOISTURE WHEN IN CONTACT WITH AIR LEAVE THE BRAKE FLUID RESER VOIR OPEN ONLY FOR THE TIME NEEDED TO COMPLETE THE TOPPING UP PROCEDURE NOTE TO AVOID SPILLING BRAKE FLUID WHILE TOPPI
7. SERVICE STATION MANUAL 854279 SCARABEO 50 4T 4V SERVICE STATION SCARABEO 50 4T 4V THE VALUE OF SERVICE Due to the continuous technical updates and specific mechanic training programs for aprilia products only aprilia Official Network mechanics know this vehicle fully and have the special tools necessary to carry out maintenance and repair operations correctly The reliability of the vehicle also depends on its mechanical state Checking the vehicle before riding its regular maintenance and using only Original aprilia Spare Parts are essential For information about the nearest Official Dealer and or Service Centre consult the Yellow Pages or search directly from the map on our Official Website www aprilia com Only by requesting aprilia Original Spare Parts can you be sure of purchasing products that were developed and tested together with the actual vehicle itself All aprilia Original Soare Parts undergo quality control procedures to guarantee reliability and durability The descriptions and illustrations given in this publication are not binding While the basic characteristics as described and illustrated in this booklet 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 m
8. 0 041 mm Refitting the driving pulley Manually detach the movable driven half pulley by pulling it towards the clutch unit fit the belt ob serving the direction of rotation of the initial as sembly NOTE IT IS GOOD PRACTICE TO ALWAYS FIT THE BELT WITH THE WORDS FACING THE OUTSIDE UNLESS AN ASSEM BLY DIRECTION IS INDICATED Refit the unit components roller housing unit with bushing limiting washer fixed half pulley cooling fan belt with drive washer and nut Tighten the lock nut to the prescribed torque so that the driving pulley does not rotate using the specific tool NOTE REPLACE THE NUT WITH A NEW ONE AT EVERY REFIT CAUTION WHEN FIXING THE DRIVING PULLEY UNIT THE BELT MUST BE FREE INSIDE IN ORDER TO AVOID A WRONG TIGHTENING THAT MAY RESULT IN SUBSEQUENT DAM AGE OF THE CRANKSHAFT KNURLING Specific tooling 020451Y starting sprocket lock Locking torques N m Driving pulley nut 40 44 ENG 93 Engine SCARABEO 50 4T 4V Refitting the transmission cover Check the following for wear toothed section toothed section shaft cover bushing pinion shaft and its seating in the crankcase and the return spring Replace the damaged components Grease the spring es Remove the toothed sector by loading the spring 7777 We x with an appropriate tool Refit the washer the Seeger ring and the Kick starter lever Recommended products AGIP GREASE MUS Driving gear odo
9. 1 Screw fixing carburettor protection to engine M6x16 1 Screw fixing rear brake retention plate M6x20 1 Crankcase half union screw Rear hub cover screws Hub oil drain screw Crankcase cooling cover screw Starting lever screw Transmission cover screws otarter motor screws Screws fixing cables to starter motor Carburettor manifold clamp screw Intake manifold screw CHAR 14 Torque in Nm 10 Nm 7 38 Ibf ft 10 Nm 7 38 Ibf ft 42 Nm 30 98 Ibf ft Torque in Nm 12 5 Nm 9 22 Ibf ft 42 Nm 30 98 Ibf ft 6 5 Nm 4 79 Ibf ft 90 90 8 Nm 5 90 Ibf ft 19 Nm 14 01 Ibf ft 90 57 5 Nm 42 41 Ibf ft 7 Nm 5 16 Ibf ft 42 Nm 30 98 Ibf ft 1 Nm 0 74 Ibf ft 1 5 Nm 1 11 Ibf ft 26 5 Nm 19 55 Ibf ft 26 5 Nm 19 55 Ibf ft 7 Nm 5 16 Ibf ft 12 Nm 8 85 Ibf ft 36 Nm 26 55 Ibf ft 5 Nm 3 69 Ibf ft 10 Nm 7 38 Ibf ft Loctite 243 9 Nm 6 64 Ibf ft 12 Nm 8 85 Ibf ft 4 Nm 2 95 Ibf ft 2 Nm 1 48 Ibf ft 12 Nm 8 85 Ibf ft 12 Nm 8 85 Ibf ft 12 Nm 8 85 Ibf ft 2 Nm 1 47 Ibf ft 1 4 Nm 1 03 Ibf ft 8 Nm 5 9 Ibf ft SCARABEO 50 4T 4V Name Oil sump screws Torque in Nm 9 Nm 6 64 Ibf ft Characteristics screw fixing oil pump to crankcase Oil pump sprocket gear screw Oil decantation labyrinth plate screw 5 5 Nm 4 06 lof ft 9 Nm 6 64 Ibf ft 7 5 Nm 5 53 Ibf ft Timing chain oil pump compartment cover screw 45Nm 332lbfft o Oil p
10. CHECK THE TIGHTENING TORQUES OF FASTENING PARTS ON A REGULAR BASIS AND AL WAYS USE A TORQUE WRENCH TO REASSEMBLE THESE COMPONENTS IF THESE RECOMMENDATIONS ARE NOT COMPLIED WITH ONE OF THE COMPONENTS MAY BECOME LOOSE AND EVEN DETACHED THUS BLOCKING A WHEEL OR OTHERWISE COM CHAR 10 SCARABEO 50 4T 4V Characteristics PROMISING THE VEHICLE S MANOEUVRABILITY THIS CAN LEAD TO FALLS WITH THE RISK OF SERIOUS INJURY OR DEATH Vehicle identification Quote the chassis number when purchasing spare parts NOTE DO NOT OBLITERATE OR ALTER THE VEHICLE IDENTIFICATION NUMBERS DOING SO IS CONSIDERED AN OFFENCE IN ALL COUNTRIES FURTHERMORE ALTERING THE IDENTIFI CATION NUMBERS INVALIDATES THE WARRANTY Chassis number The chassis number 1 is marked on the chassis central bar Remove the cover 2 to read it Engine number The engine number 3 is marked near the lower support of the rear shock absorber Dimensions and mass SIZES Specification Desc Quantity Max length 1905 mm 75 in Max width to brake levers 705 mm 27 7 in Max height to the rear view mirrors 1190 mm 46 9 in Saddle height 700 mm 27 6 in Wheelbase 1245 mm 49 in Minimum ground clearance 140 mm 5 5 in Kerb weight in running order 100 kg 220 5 Ib Engine ENGINE Specification Desc Quantity Engine model C37AM Type 4T 4V CHAR 11 Characteristics Specification Number of cylinders Overall engine capacity Bore stroke
11. ENG 126 SCARABEO 50 4T 4V Engine Removal Remove the chain compartment cover by undo ing the 3 fixing screws indicated in the figure Take out the cover using the appropriate fusion couplings on the cover with a pair of pliers Remove the cover of the pump control crown gear by undoing the 2 retainers indicated in the figure Block the rotation of the oil pump control gear by inserting a screwdriver through one of the holes on the pump Remove the central screw and the belleville washer Remove the chain and the sprocket gear Remove the crankshaft control pinion Remove the oil pump by unscrewing the 2 re tainers indicated in the figure Remove the sealing gasket IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO EN SURE THAT THE DIRECTION OF ROTATION IS MAIN TAINED Inspection Remove the two screws and the oil pump cover Remove the circlip fixing the inner rotor Remove and wash the rotors thoroughly with de greasing solvent and compressed air Reassemble the rotors in the pump body keep ing the 2 reference marks visible Fit the retainer ring ENG 127 Engine SCARABEO 50 4T 4V Measure distance between rotors inner rotor outer rotor with a feeler gauge in the position shown in the picture Characteristic Limit clearance allowed 1 0 15 mm Measure the distance between the outer rotor and the pump body see figure Characteristic Limit clearance a
12. EXHAUST Specification Desc Quantity Standard clearance 0 025 0 052 mm Limit allowed 0 07 mm If no faults are found during the above checks the same valves can be reused For better sealing results we recommend grinding the valve seats Grind the valves gently with fine grained lapping com pound Upon grinding keep the cylinder head in horizontal position This will prevent the lapping compound residues from penetrating between the valve stem and the guide see figure CAUTION TO AVOID SCORING THE FAYING SURFACE DO NOT ROTATE THE VALVE WHEN NOLAPPING COMPOUND IS LEFT CAREFULLY WASH THE CYLINDER HEAD AND THE VALVES WITH A SUITABLE PRODUCT FOR THE TYPE OF LAPPING COMPOUND BEING USED CAUTION DO NOT CHANGE THE VALVE FITTING POSITION RH LH CHAR 27 Characteristics SCARABEO 50 4T 4V Check the camshaft bearings for signs of abnor mal wear Characteristic Standard diameter Bearing A 12 0 002 40 010 mm Standard diameter Bearing B 16 0 015 0 023 mm Minimum diameter allowed Bearing A 11 98 mm Minimum diameter allowed Bearing B 15 96 mm Using a gauge measure the height of the cams Check camshaft axial clearance If values measured are not within the specified limits or there are signs of excessive wear replace the defective components with new ones NOTE A BALL BEARING IS FITTED ON BEARING A CONSE QUENTLY BEARING B IS THE MOST IMPORTANT AS IT WORKS DI
13. Fit the maximum jet Check that the tapered pin does not show signs of wear on the damped pin sealing surface and the return spring Replace the pin if it is worn Check that the float is not worn on the pin housing or on the plate in contact with the pin and that there are no fuel leaks on the carburettor Replace it in case of faults Fit the float together with the pin and rod in its position and lock it with the appropriate screw NOTE FIT THE RETURN SPRING ON THE FLOAT PLATE ADE QUATELY Fit the ball in the corresponding accelerating pump Fit the spring Fit the accelerating pump jet WARNING WHEN REFITTING PAY SPECIAL ATTENTION TO THE COMPONENTS AS THEY ARE SMALL ENG 135 Engine SCARABEO 50 4T 4V Check the diaphragm is in good conditions and remove the remaining components of the acceler ating pump following these steps Fit the O Ring in the pipe Fit the diaphragm together with the pin and the corresponding spring NOTE REPLACE THE DIAPHRAGM IF THERE ARE SIGNS OF UN DULATIONS CRACKS OR EXCESSIVE HARDENING Fit the accelerating pump diaphragm cover and tighten the 2 fixing screws making sure the spring below is correctly positioned Fit the rubber bellows protecting the pin in the upper part of the accelerating pump Level check Tilt the carburettor so that the petrol supply nee dle valve is closed and the float weight does not affect it
14. IF IT ACCIDEN TALLY COMES INTO CONTACT WITH YOUR EYES OR SKIN WASH WITH ABUNDANT WATER FOR APPROX 15 MIN AND SEEK MEDICAL ATTENTION IMMEDIATELY IF ACCIDENTALLY SWALLOWED IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR MILK FOLLOWED BY MAGNESIUM MILK BEATEN EGG OR VEGETABLE OIL SEEK MEDICAL ATTENTION IMMEDIATELY BATTERIES PRODUCE EXPLOSIVE GASES KEEP CLEAR OF NAKED FLAMES SPARKS OR CIGARETTES VENTILATE THE AREA WHEN RECHARGING INDOORS ALWAYS WEAR EYE PROTECTION WHEN WORKING IN THE PROXIMITY OF BATTERIES KEEP OUT OF THE REACH OF CHILDREN Remove the short closed tube and the caps then pour sulphuric acid into the cells using the type specified for bat teries with a specific gravity of 1 26 corresponding to 30 B at a minimum temperature of 15 C until the upper level is reached Leave to rest for at least 2 hours then restore the level with sulphuric acid Within the following 24 hours recharge with the specific battery charger at an intensity of about 1 10 of the battery nominal capacity and until the acid density is about 1 27 corresponding to 31 B and these values are stabi lised ELE SYS 75 Electrical system SCARABEO 50 4T 4V Once the charge is complete level the acid by adding distilled water Close and clean carefully Once the above operations have been performed install the battery on the ve hicle ensuring that it is connected prop erly 1 Hold the tube upright
15. 2 Inspect visually 3 The float must be freed Electrolyte level check The electrolyte level must be checked frequently and must reach the upper level Only use distilled water to restore this level If it is necessary to add water too frequently check the vehicle electrical system the battery works overcharged and is subject to quick wear Charge status check After topping up the electrolyte level check its density using an appropriate densitometer With the battery charged a density of 30 32 B corresponding to a specific weight 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 be used for a certain time 1 month or more the battery needs to be recharged periodically The battery runs down completely in about three months Should the battery be fitted on a vehicle be careful not to invert the connections keeping in mind that the black ground wire marked is con nected to the negative terminal while the other two red wires marked are connected to the positive terminal Battery recharge WARNING BEFORE RECHARGING THE BATTERY REMOVE THE CAPS OF EACH CELL KEEP NAKED FLAMES OR SPARKS AWAY FROM THE BATTERY WHILE CHARGING First detach the negative terminal before removing the battery from the vehicle Normal bench charging must be performed using the special battery charger setting the b
16. 50 4T 4V Chassis Pilot lights kit Replace the instrument panel bulbs NOTE BEFORE CHANGING A BULB CHECK THE FUSES e Remove the front handlebar cover Replace the warning light bulbs Turn indicators 1 green Low beam warning light 2 green High beam light 3 blue Take and replace the bulb with another of the same type Replace the dashboard lighting bulbs x Upper right lighted section 4 Lower left lighted section 5 Take and replace the bulb with another of the same type NOTE TAKE OUT THE BULB HOLDERS ONE AT A TIME TO AVOID PLACING THEM INCORRECTLY WHEN REFITTING Lower cover e Park the vehicle on its centre stand e Remove the 6 screws indicated e Remove the lower cover NOTE WHEN REFITTING MAKE SURE THAT THE FRONT PART OF THE LOWER SHIELD IS CORRECTLY POSITIONED CHAS 173 INDEX OF TOPICS SCARABEO 50 4T 4V Carry out the listed checks before delivering the vehicle WARNING BE EXTREMELY CAUTIOUS WHEN HANDLING FUEL Aesthetic inspection Paintwork Fitting of Plastic Parts Scratches Dirt Tightening torques inspection Safety locks front and rear Suspension unit front and rear brake calliper retainer unit front and rear wheel unit engine chassis retainers steering assembly Plastic parts fixing screws Electrical system Main switch Pre delivery Headlamps high beam lights low beam lights tail lights
17. CLOSING THEM WITH A VICE AS NEE DED IF EVEN AFTER THIS OPERATION THE VALUES ARE NOT THOSE ADMITTED REPLACE THE CRANKSHAFT Characteristic Maximum off line allowed A 0 15 mm Maximum off line allowed B 0 02 mm Maximum off line allowed C 0 02 mm Maximum off line allowed D 0 10 mm Check that the crankshaft cone the tab fitting the oil seal flow the knurling and the threaded shanks are in good working order In case of failure replace the crankshaft Specific tooling 020074Y Support base for checking crankshaft alignment Refitting the crankcase halves Be careful to place the two alignment dowels preferably on the crankcase halves on the flywheel side Fit the crankshaft on the crankcase halves on the transmission side ENG 124 SCARABEO 50 4T 4V Engine Fit the gasket recommended for surfaces on the F crankcase half on the transmission side after greasing the two faying surfaces carefully Fit the crankcase half on the flywheel side Fit the 10 screws and tighten them to the pre scribed torque NOTE WHEN FITTING THE CRANKCASE HALVES AND THE CRANKSHAFT BE CAREFUL NOT TO DAMAGE THE SHAFT THREADED SHANKS Recommended products Loctite 510 Liquid sealant Gasket Locking torques N m Crankcase halves union screws 8 10 Nm Fit a new O Ring on the mesh oil filter and on the filler plug lubricate Fit the filter on the engine and lock the cap to the prescr
18. Clamp qs me OLIUEENEEEE Ear E AT Electrical system ELE SYS 59 Electrical system SCARABEO 50 4T 4V Back side A Cable harness routing to the engine s A LAT LM B Cable harness routing to the chassis area 1 Clamp 2 Air solenoid positioning ELE SYS 60 SCARABEO 50 4T 4V Electrical system 3 Clamp optional 4 Mudguard crest ELE SYS 61 Electrical system SCARABEO 50 4T 4V 5 WARNING Fit the connector completely until an end of stroke click is heard ELE SYS 62 SCARABEO 50 4T 4V Electrical system 6 Engine head temperature cable routing Correct fitting of the cap ELE SYS 63 Electrical system Layout of the relay and fuses SCARABEO 50 4T 4V e 4030 7 09 I ANEDI 641735 0800050000152 AH ELE SYS 64 SCARABEO 50 4T 4V Electrical system Checks and inspections ELE SYS 65 Electrical system SCARABEO 50 4T 4V Ignition circuit All the control operations of the system that require the disconnection of cables checks of the connec tions and the devices making up the ignition circuit must be done with the engine off if this is not done the control unit might be irretrievably damaged In case the cause of ignition failure or malfunction cannot be easily identified at sight first of all re place the control unit by another one in operating conditions Remember that disconnection due to replacement of the cen
19. Compression ratio Standard carburettor Ignition Clutch Gearbox Cooling Ignition type Ignition advance Spark plug Spark plug electrode gap Engine revs at idle speed Valve clearance when cold Transmission Specification Variator Primary drive secondary TRANSMISSION Minimum ratio for continuos transmission Maximum ratio for continuos transmission Capacities Specification Fuel reserve included Fuel reserve Transmission oil CAPACITY Engine oil engine oil change and engine oil filter replacement Seats SCARABEO 50 4T 4V Desc Quantity Horizontal single cylinder 49 9 cm 3 04 cu in 39 mm 41 8 mm 11 5 up to 12 1 KEIHIN NCV20 electric kick starter centrifugal continuous and automatic variator with forced air CDI Variable from 0 to 28 NGK ER9EH N 0 6 0 7 mm 1 800 100 rpm intake 0 10 mm exhaust 0 15 mm Desc Quantity continuous automatic V belt gear reduction unit 3 07 0 87 Desc Quantity 7 1 84 gal 11 0 2 gal 100 cm 6 1 cu in 850 cm 51 8 cu in No 1 2 in countries where passenger transport is permitted Vehicle max load rider passenger luggage Electrical system Specification Battery Fuse O o NIIAJ Go Po CHAR 12 ELECTRICAL SYSTEM Permanent magnet alternator Low high beam light bulb Turn indicators bulbs Rear tail light stop light bulb Instrument panel light bulbs High beam warning light Turn indicator warning light 18
20. and collar are not worn refit the pins and the collar Using a curved spout grease gun lubricate the driven pulley unit with approximately 6 g of grease Apply the grease through one of the holes in the bushing until grease comes out through the hole on the opposite side This procedure is necessary to prevent the presence of grease beyond the O rings Recommended products AGIP GREASE SM 2 Grease for C ring of the tone wheel Soap based lithium grease with NLGI 2 molybdenum disulphide ISO L XBCHB2 DIN KF2K 20 Refitting the driven half pulley bearing Fit a new ball bearing with the specific tool Fit the ball bearing snap ring Fit the new roller bearing with the words facing the outside CAUTION PROPERLY SUPPORT THE HALF PULLEY TO PREVENT DAMAGING THE THREADED END WHILE THE BEARINGS ARE BEING FITTED Specific tooling 020376Y Adapter handle 020456Y 24 mm adaptor 020362Y 12 mm guide 020171Y Punch for 17 mm roller bearing ENG 89 Engine SCARABEO 50 4T 4V Inspecting the clutch spring Check that the driven pulley supporting spring is not deformed b ran S nr t 2 TUBE coa e Perieg z TON RR RU ipe Measure the unloaded spring length Characteristic Standard length 118 mm Minimum length allowed after use XXXX Check the thickness of the clutch mass friction material he masses must not show traces of lubricants otherwise check the driven pulley unit NOTE UPON RUNNING
21. back Loosen the clamping nut 2 Turn regulator 3 so as to restore the specified value After adjusting tighten the closing nut 2 and check backlash again Refit the rubber sheathing 1 CAUTION uN AFTER ADJUSTING THE THROTTLE GRIP TURN THE HANDLEBAR FULLY TO THE LEFT AND THEN FULLY TO THE RIGHT WITH THE ENGINE AT IDLE SPEED CHECK THAT THE NOISE PRODUCED WITH THE ENGINE AT IDLE DOES NOT CHANGE WHILE CARRYING OUT THESE OPERATIONS ALSO CHECK THAT THE THROT TLE GRIP CLOSES SMOOTHLY AND TOTALLY WHEN RE LEASED MAIN 48 SCARABEO 50 4T 4V Maintenance Checking the valve clearance Remove the rear central cover Loosen and remove the 4 screws indicated in the figure and remove the tappet cover To check valve clearance centre the reference marks of the timing system point Check that valve clearances are correct with a feeler gauge If the valve clearance values intake and exhaust respectively differ from those indicated below re place the calibrated pads in order to restore the correct valve clearance Characteristic Intake with cold engine 0 10 mm Exhaust with cold engine 0 15 mm Braking system CAUTION IT IS STRICTLY NECESSARY AFTER REFITTING BRAKES AND RESTORING THE BREAKING SYSTEM TOITS REGULAR USE CONDITIONS THAT THE HYDRAULIC CIRCUIT BE AIR PURGED Level check NOTE CARRY OUT THESE OPERATIONS ONLY WITH THE VEHICLE ON A FLAT AND STABLE SUR
22. not start Sealed battery Installing the sealed battery without maintenance In case the vehicle fits a sealed battery the maintenance is limited to the loading state and to an eventual recharge This operations should be performed in the vehicle pre delivery phase and every six months of open circuit storage Therefore in addition to pre delivery it is necessary to check the load and carry on the eventual recharge before the vehicle storage and afterwards every 6 months INSTRUCTIONS FOR BATTERY REFRESH AFTER OPEN CIRCUIT STORAGE 1 Voltage check 2 Before installing the battery on the vehicle check the open circuit voltage with a standard tester If voltage is over 12 60V the battery can be installed without any refresh ELE SYS 74 SCARABEO 50 4T 4V Electrical system If voltage is below 12 60 V a renewal recharge is required as explained in 2 3 Constant voltage battery charge mode e Constant voltage charge equal to 14 40 14 70V Initial charge current equal to 0 3 0 5 of the battery rated capacity Charge time e 10 to 12 h recommended Minimum 6 h Maximum 24 h C1 Constant current battery charge mode D Charge current equal to 1 10 of the battery rated capacity Dry charge battery Installing the dry charge battery with maintenance WARNING BATTERY ELECTROLYTE IS POISONOUS AS IT MAY CAUSE SERIOUS BURNS IT CONTAINS SULPHURIC ACID AVOID CONTACT WITH YOUR EYES SKIN AND CLOTHING
23. r mm m m m m m r r 2J 2J 2ZIi r 0l OlO r r 2J 2J Zi r 0 l OlO r ir d iadJIiz i ir r ir di idxJIz i ir S S d D jr Carburettor Solenoid valve The carburettor features a solenoid valve A that via an ECU manages an extra flow of air It is connected to the carburettor via flexible pipes as shown in the figure The valve is placed under the helmet compartment as shown in the picture Remove the rear central cover to reach it Pipe B is coupled to a filter placed inside the fuse box The solenoid filter should be cleaned accord ing to the kilometres travelled as indicated in the scheduled maintenance chart MAIN 39 Maintenance SCARABEO 50 4T 4V Idle speed adjustment Check idle speed according to the indications in the maintenance table To reach the set screw e Remove the rear central cover CAUTION BEFORE CARRYING OUT THE FOLLOWING OPERATIONS AND IN ORDER TO AVOID BURNS LEAVE ENGINE AND SILENCER TO COOL OFF TO AMBIENT TEMPERATURE Operate on the screw 1 until the pre set idle speed is obtained Characteristic Engine revs at idle speed 1 800 100 rom Checking the spark advance The vehicle is fi
24. the front brake lever under the upper handlebar cov er CAUTION NEVER USE THE SCOOTER IF THERE IS A FLUID LEAK ON ANY SYSTEM PART a ET i CAUTION WHEN PADS ARE WORN THE BRAKE FLUID LEVEL DECREASES PROGRESSIVELY TO COM PENSATE PAD WEAR If the fluid does not reach the MIN reference mark Check brake pads for wear If there is no need to replace any pads discs check the braking system to determine the cause of the problem by checking if the brake cables are in good conditions Mainly check if there are broken or cracked areas the connections are properly tightened e the connections may exhibit leaks the calliper and the reservoir may exhibit leaks the bleed screw may exhibit leaks If dripping is detected tighten to the appropriate tight ening torque e the fuel tank caps for possible leaks and the gaskets conditions After repairing the brake e Check and bleed the system Top up the reservoir with a proper brake fluid BRAK SYS 156 SCARABEO 50 4T 4V Braking system Front brake calliper Removal CAUTION NEVER OPERATE THE FRONT BRAKE LEVER ONCE THE CALLIPER IS REMOVED SINCE THIS MAY CAUSE THE PISTONS TO COME OUT AND CALLIPER BRAKE FLUID TO LEAK e Undo the two screws indicated and re m f move the brake calliper CAUTION A d AFTER REFITTING PULL THE FRONT BRAKE LEVER RE P J E PEATEDLY AND CHECK THAT THE BRAKING SYSTEM OPERATES CORRECTLY Y
25. 0 4T 4V Torque in Nm 0 5 Nm 0 37 Ibf ft Torque in Nm 2 Nm 1 47 Ibf ft 8 Nm 5 90 Ibf ft 1 Nm 0 74 Ibf ft 2 Nm 1 47 Ibf ft qq Torque in Nm 3 Nm 2 21 Ibf ft 1 Nm 0 74 Ibf ft 1 Nm 0 74 Ibf ft 2 Nm 1 47 Ibf ft qq fe n HEAD INSTRUMENT PANEL UNIT Name Turn indicator self tapping retainer to front hand cover M5 2 TBEI screw fixing instrument panel to rear hand cover 2 9x12 4 TBEI screw fixing rear hand cover to handlebar 2 9x12 3 TBEI screw fixing rear hand cover to front handlebar cover 2 9x12 6 ELECTRICAL SYSTEM UNIT Name Battery compartment fixing screw M5x12 1 Battery compartment cover fixing screw M5x12 1 Ground lead fixing screw M6x12 1 Coil fixing screw M5x20 2 Nut fixing relay support to legshield M5 1 Voltage regulator fixing screw M5x20 2 Key switch fixing screw M6x16 1 TANK UNIT Name ocrew fixing fuel cock to battery compartment M5x16 1 Clamp fixing fuel pipe to tank Diam 16 1 Screw fixing carburettor protection plate M5x10 2 Fuel cock fixing screw M5x16 1 LOCK UNIT Name Nut fixing locks to helmet compartment M6 2 Nut fixing glove box lid locks M19x1 1 Overhaul data Assembly clearances CHAR 16 Torque in Nm 1 5 Nm 1 11 Ibf ft 0 5 Nm 0 37 Ibf ft 0 5 Nm 0 37 Ibf ft 0 5 Nm 0 37 Ibf ft Torque in Nm 5 Nm 3 69 Ibf ft 3 Nm 2 21 Ibf ft 10 Nm 7 38 Ibf ft 3 Nm 2 21 Ibf ft 2 Nm 1
26. 0 kg 396 8 Ib Desc Quantity 12V 9 Ah 7 5A 13 V 120 W 12 V 35 35 W 12V 10W 12V 5 21W 12V 1 2W 12V 1 2W 12V 3W SCARABEO 50 4T 4V Frame and suspensions Specification Size A Size B Steering rake angle Chassis type Front suspension Travel Rear suspension Travel Brakes Specification Front Rear Wheels and tyres Specification Type Front Rear Specification Front tyre Rear tyre Standard inflation pressure Inflation pressure with passenger in countries where passen ger transport is permitted Characteristics CHASSIS AND SUSPENSIONS Desc Quantity 446 mm 471 5 mm 24 split double cradle frame Hydraulic action telescopic fork 89 mm 3 5 in single hydraulic shock absorber 74 mm 2 9 in BRAKES Desc Quantity 220 mm 8 66 in disc brake with hydraulic transmission 140 mm 5 51 in drum brake WHEEL RIMS Desc Quantity alloy 1 60 x16 1 85 x 16 TYRES Desc Quantity 80 80 x 16 SAVA MC 26 CAPRI 46M REINF 90 80 x 16 SAVA MC 26 CAPRI 52M REINF Front 190 kPa 1 9 bar 27 55 psi Rear 220 kPa 2 2 bar 31 9 psi Front 190 kPa 1 9 bar 27 55 psi Rear 230 kPa 2 3 bar 33 35 psi CHAR 13 Characteristics Tightening Torques LINK ROD UNIT Name Nut fixing link rod to chassis M10 1 Nut fixing link rod to engine M10 1 FRAME ASSEMBLY Name screw fixing shock absorber to chassis M10x45 1 Nut fixing passenger foot
27. 029 Bell for 38 mm outside diameter bearings ENG 87 Engine Remove the ball bearing retaining circlip Extract the ball bearing from the clutch housing side using the specific tool NOTE PROPERLY SUPPORT THE HALF PULLEY SO AS NOT TO DEFORM THE SLIDING SURFACE OF THE DRIVING BELT Specific tooling 020376Y Adapter handle 020363Y 20 mm guide Inspecting the driven fixed half pulley Check that there are no signs of wear on the belt work surface If there are replace the half pulley Make sure the bearings do not show signs of ab normal wear Measure the outside diameter of the pulley bush ing Characteristic Fixed driven half pulley Standard diameter 33 965 33 985 mm Fixed driven half pulley Minimum diameter al lowed after use 33 96 mm Inspecting the driven sliding half pulley Remove the 2 inner sealing rings and the 2 O rings Measure the inside diameter of the movable half pulley bushing Characteristic Movable driven half pulley Maximum diameter allowed 34 08 mm ENG 88 SCARABEO 50 4T 4V SCARABEO 50 4T 4V Engine Check the belt faying surfaces Fit the new oil seals and O rings on the movable half pulley Fit the half pulley on the bushing Recommended products AGIP GREASE SM 2 Grease for C ring of the tone wheel Soap based lithium grease with NLGI 2 molybde num disulphide ISO L XBCHB2 DIN KF2K 20 Make sure the pins
28. 46 0 032 0 046 0 032 0 046 0 032 0 046 0 032 0 046 0 032 0 046 0 032 0 046 0 032 0 046 0 032 0 046 PISTON RINGS MUST BE FITTED WITH THE REFERENCE TOP OR THE STAMPED MARK FACING UPWARDS Check the pin outside diameter Characteristic Pin outside diameter 13 0 0 004 mm Minimum diameter allowed pin 12 990 mm CHAR 17 Characteristics SCARABEO 50 4T 4V Measure the diameter of the bearings on the pis ton Characteristic Pin seat diameter 13 0 005 0 010 mm Calculate the pin piston coupling clearance NOTE THE PIN HOUSINGS HAVE TWO LUBRICATION CHANNELS FOR THIS REASON MEASURE THE DIAMETER ACCORDING TO THE PISTON AXIS Characteristic Standard clearance 0 005 0 014 mm Carefully clean the sealing rings housings Measure the sealing rings pistons coupling clearance using suitable sensors as shown in the diagram If clearances measured exceed the limits speci fied in the table below the piston should be re placed by a new one NOTE MEASURE CLEARANCE BY INSERTING THE BLADE OF THE FEELER GAUGE FROM THE 2nd SEALING RING SIDE Fitting clearance 1st compression ring standard coupling clearance 0 03 0 065 mm 1st compression ring maximum clearance allowed after use 0 07 mm 2nd compression ring standard coupling clearance 0 02 0 055 mm 2nd compression ring maximum clearance allowed after use 0 06 mm oil scraper standard coupling clea
29. 47 Ibf ft 5 Nm 3 69 Ibf ft 10 Nm 7 38 Ibf ft Torque in Nm 5 Nm 3 69 Ibf ft 3 Nm 2 21 Ibf ft 3 Nm 2 21 Ibf ft 3 Nm 2 21 Ibf ft qq Torque in Nm 5 Nm 3 69 Ibf ft 5 Nm 3 69 Ibf ft SCARABEO 50 4T 4V Cylinder piston assy Name Cylinder Cylinder Piston Piston Cylinder 1st oversize Cylinder 1st oversize Piston 1st oversize Piston 1st oversize Cylinder 2nd oversize Cylinder 2nd oversize Piston 2nd oversize Piston 2nd oversize Cylinder 3rd oversize Cylinder 3rd oversize Piston 3rd oversize Piston 3rd oversize NOTE THE PISTON MUST BE FITTED WITH THE ARROW FACING TOWARDS THE EXHAUST SIDE THE Initials A B C D A1 B1 C1 D1 A2 B2 C2 D2 A3 B3 C3 D3 Cylinder 38 993 39 000 39 000 39 007 39 007 39 014 39 014 39 021 39 193 39 200 39 200 39 207 39 207 39 214 39 214 39 221 39 393 39 400 39 400 39 407 39 407 39 414 39 414 39 421 39 593 39 600 39 600 39 607 39 607 39 614 39 614 39 621 COUPLING BETWEEN PISTON AND CYLINDER Piston 38 954 38 961 38 961 38 968 38 968 38 975 38 975 38 982 39 154 39 161 39 161 39 168 39 168 39 175 39 175 39 182 39 354 39 361 39 361 39 368 39 368 39 375 39 375 39 382 39 554 39 561 39 561 39 568 39 568 39 575 39 575 39 582 Characteristics Play on fitting 0 032 0 046 0 032 0 046 0 032 0 046 0 032 0 046 0 032 0 046 0 032 0 046 0 032 0 046 0 032 0 0
30. A 12 0 002 0 010 mm Standard diameter Bearing B 16 0 015 0 023 mm Minimum diameter allowed Bearing A 11 98 mm Minimum diameter allowed Bearing B 15 96 mm Using a gauge measure the height of the cams Check camshaft axial clearance If values measured are not within the specified limits or there are signs of excessive wear replace the defective components with new ones NOTE A BALL BEARING IS FITTED ON BEARING A CONSE QUENTLY BEARING B IS THE MOST IMPORTANT AS IT WORKS DIRECTLY ON THE ALUMINIUM OF THE HEAD Characteristic Standard height Intake 24 397 mm Standard height Exhaust 23 996 mm Fitting clearance Maximum axial clearance allowed 0 5 mm Check the outside diameter of the rocker pins Check there are no signs of wear or scoring on the rocker pins Check the internal diameter of each rocker arm Check that the pad in contact with the cam is not worn DIAMETER OF PINS AND ROCKING LEVERS Specification Desc Quantity Rocking lever inner diameter 11 015 11 035 mm Rocking lever pin diameter 10 977 10 985 mm ENG 117 Engine SCARABEO 50 4T 4V Refitting the head and timing system components Rest the head steadily on a work table Screw the tool to fit the camshaft fully down on the bearing inner track Push it fully down into its seating together with the bearing with the aid of a mallet Remove the tool Fit the head gaske
31. ACCIDENTALLY Remove the 3 fixing screws and the float cham ber with the corresponding gasket ENG 131 Engine SCARABEO 50 4T 4V Remove the float chamber components following the procedure below Undo the 2 screws fixing the accelerating pump diaphragm cover Remove the cover being careful with the spring below then remove the spring take out the rubber protection and the diaphragm together with the pipe O Ring Remove the accelerating pump jet and the ball spring Remove the screw shown in the figure fixing the float pin Remove the float and the pin Remove the maximum jet Remove the diffuser ENG 132 SCARABEO 50 4T 4V Engine Remove the minimum jet Remove the sprayer tilting the carburettor body NOTE THIS OPERATION IS NECESSARY TO AVOID LOSING SPRAYER PARTS WHEN CLEANING THE CARBURETTOR BODY IF THE SPRAYER IS FORCED INTO ITS POSITION DO NOT ATTEMPT TO REMOVE IT AS THIS WILL ONLY DAMAGE IT Remove the idle flow screw with the O ring and the spring CAUTION DO NOT TRY TO REMOVE PARTS EMBEDDED IN THE CARBURETTOR BODY SUCH AS THE FUEL SUPPLY PIPE THE PIN SEAT THE STARTER JET THROTTLE VALVE CONTROL SHAFT DO NOT REMOVE THROTTLE SHAFT CONNECTION SCREWS THE FIXING SCREWS ARE CHAMFERED AFTER BEING FITTED AND REMOVING THEM DAMAGES THE SHAFT ENG 133 Engine SCARABEO 50 4T 4V Refitting the carburettor Before refitting wash the carbu
32. BEO 50 4T 4V The starter should be progressively disconnected P by means of electrical heating Check the starter resistance when adjusted to the ambient temperature Characteristic ambient temperature 24 C Electric characteristic Automatic starter resistance 2004 5 Use battery to power the automatic starter and check that piston protrudes as much as possible The correct warm up time depends on the ambi ent temperature f protrusion resistance or timing values are dif ferent from the ones prescribed replace the start er Characteristic Battery 12V 9 Ah max protrusion 15 mm max time 15 min Fit the starter the support bracket and the pro tection with the screw shown in the figure ENG 138 SCARABEO 50 4T 4V Engine Fit rubber pipes for float chamber ventilation Fit the O Ring the washer the spring and the minimum flow screw in the corresponding seat Refit the carburettor on the engine and connect again the throttle grip cable with the sheath and the support plate and the starter electrical connec tion Reconnect the petrol supply pipe and tighten the 2 fixing screw clamps that fix the carburettor to the inlet manifold and the air inlet sleeve to the filter Adjusting the idle The engine does not require frequent idle soeed adjustments but it is essential to strictly follow certain rules when adjusting the idle speed Before adjusting t
33. CRANKSHAFT MIGHT ACCIDENTALLY FALL IF THIS RULE IS NOT OBSERVED Remove the flywheel side oil seal CAUTION THE CENTRIFUGAL OIL FILTER IS ON THE FLYWHEEL SIDE HALF SHAFT CONSEQUENTLY DO NOT WASH WITH SOLVENTS OR BLOW COMPRESSED AIR SO THAT NO IMPURITIES LEAK ENG 121 Engine SCARABEO 50 4T 4V OUT A CENTRIFUGAL OIL FILTER LIFE IS THE SAME AS THE ENGINE S AND IS MAINTE NANCE FREE Check the connecting rod axial clearance Fitting clearance Connecting rod standard axial clearance 0 15 0 30 mm Connecting rod maximum axial clear ance 0 5 mm Check the correct radial clearance of the con necting rod Holding the crankshaft with your hands and with a dial gauge fitted to the connect ing rod small end measure clearance by moving the connecting rod vertically as shown in the fig ure Fitting clearance Connecting rod standard radial clearance 0 006 0 018 mm Connecting rod maximum radial clearance 0 25 mm Check that the half shaft surfaces are not scored and with the aid of a gauge measure the crank shaft width as shown in the figure Characteristic Standard measure 45 mm Removing the crankshaft bearings Remove the flywheel side bearing fitted on the crankshaft using the specific tool Specific tooling 004499Y Shaft bearing extractor 004499Y001 Bell for bearing extractor 004499Y002 Screw for bearing extractor 004499Y006 Ring for bearing extractor 004499Y034 part for the beari
34. D IN ITS SEAT DO NOT USED COMPRESSED AIR TO CLEAN BEARINGS NOTE BEARINGS MUST ROTATE FREELY WITHOUT JAMMING AND OR NOISE OTHERWISE THEY NEED TO BE REPLACED 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 either from the components with the largest diameter or from the innermost components proceeding diagonally Tighten nuts and screws in suc cessive steps before applying the tightening torque Always replace self locking nuts washers sealing rings circlips O rings OR cotter pins and screws with new parts if the thread is damaged When assembling the bearings make sure to lubricate them well Check that each component is assembled correctly After a repair or routine maintenance carry out pre ride checks and test the vehicle on private grounds or in an area with low traffic Clean all mating surfaces oil seal rims and gaskets before refitting Smear a thin layer of lithium based grease on the oil seal rims Reassemble the oil seal and the bearings with the brand or lot number facing outward visible side TIGHTENING TORQUES CAUTION DO NOT FORGET THAT TIGHTENING TORQUES OF ALL FASTENING ELEMENTS ON WHEELS BRAKES WHEEL SPINDLES AND OTHER SUSPENSION COMPONENTS PLAY A KEY ROLE IN ENSURING THE VEHICLE S SAFETY AND MUST COMPLY WITH SPECIFIED VALUES
35. EEL alternating TURN INDICATORS on A O N ELE SYS 78 INDEX OF TOPICS Enone FROM VEHICLE ENG VE Engine from vehicle SCARABEO 50 4T 4V Exhaust assy Removal e Park the vehicle on its centre stand CAUTION BEFORE CARRYING OUT THE FOLLOWING OPERA TIONS LET THE ENGINE AND THE SILENCER TO COOL OFF AT AMBIENT TEMPERATURE TO AVOID POTENTIAL BURNS o Unscrew and remove the screws 1 e Unscrew and remove the screws 2 e Remove the silencer Park the vehicle on its centre stand Remove the tail fairing Take out the spark plug tube Remove the air filter housing and the splash guard Disconnect the electrical connector 1 and the ground lead 2 from the starter motor and the alternator con nector 3 and release the cable har nesses re z e ENG VE 80 SCARABEO 50 4T 4V e Hemove the anti ice carburettor con nector 14 Disconnect the engine starter connec tor 4 and release the cable harness Remove the vacuum pipe 5 and the engine head temperature sensor 8 Disconnect the fuel pipe 6 and the solenoid pipe 13 from the carburet tor Engine from vehicle ENG VE 81 Engine from vehicle Remove the throttle grip cable 7 from the carburettor by acting on the adjuster screws e Unscrew the rear brake set screw 9 and the two screws 10 and free the brake cable
36. F WATER OR VEGETABLE OIL SEEK MEDICAL ATTENTION IMMEDIATELY BATTERIES PRODUCE EXPLOSIVE GASES KEEP CLEAR OF NAKED FLAMES SPARKS OR CIGARETTES VENTILATE THE AREA WHEN RECHARGING INDOORS ALWAYS WEAR EYE PROTECTION WHEN WORKING IN THE PROXIMITY OF BATTERIES KEEP OUT OF THE REACH OF CHILDREN CAUTION NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY USING A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE A FIRE Levels check Hydraulic braking system fluid level Rear hub oil level Engine coolant level if present Engine oil level Mixer oil level if present Road test Cold start Instrument panel operation Response to throttle control Stability when accelerating and braking PRE DE 176 SCARABEO 50 4T 4V Pre delivery Front and rear brake efficiency Front and rear suspension efficiency Abnormal noise Static test Static check after test drive Restarting when warmed up Starter operation if present Minimum holding turning the handlebar Uniform turning of the steering Possible leaks Radiator electric fan operation if present Functional inspection Hydraulic braking system Brake levers stroke Clutch Check for correct operation Engine Check for correct general operation and absence of abnormal noise Other Documentation check Chassis and engine numbers check Supplied tools check License
37. FROM THE 2nd SEALING RING SIDE Fitting clearance 1st compression ring standard coupling clearance 0 03 0 065 mm 1st compression ring maximum clearance allowed after use 0 07 mm 2nd compression ring standard coupling clearance 0 02 0 055 mm 2nd compression ring maximum clearance allowed after use 0 06 mm oil scraper standard coupling clearance 0 04 0 16 mm oil Scraper maximum clearance al lowed after use 0 17 mm ENG 108 SCARABEO 50 4T 4V Engine Inspecting the cylinder Using a bore meter measure the cylinder inside 30 diameter at three different points according to the directions shown in the figure ra ttr mE ge i gi m ee eee Check that the coupling surface with the head is not worn or distorted Pistons and cylinders are classified according to their diameter This coupling is carried out in pairs A A B B C C D D Characteristic Maximum run out allowed 0 05 mm Inspecting the piston rings Alternately fit the 3 sealing rings in the cylinder in the area where it keeps its original diameter Using the piston fit the rings perpendicularly to the cylinder axis Measure the opening of the sealing rings using a feeler gauge as shown in the figure Replace the piston rings if values higher than those prescribed are measured NOTE BEFORE REPLACING ONLY THE PISTON RINGS MAKE SURE THAT COUPLING CLEARANCE BETWEEN THE SEAL RINGS AND ITS GROO
38. Front brake pads Removal Park the vehicle on its centre stand Remove the brake calliper cover 1 Remove circlips 3 Remove cylinder 4 Remove the spring 5 NOTE THE ANTI FRICTION PLATES 6 COME OUT TOGETHER WITH THE PADS UL Take out the pads 7 together with the anti friction plates one at a time CAUTION NEVER OPERATE THE BRAKE LEVER ONCE THE CALLIPER IS REMOVED MAY CAUSE THE PISTONS TO COME OUT AND CALLIPER BRAKE FLUID TO LEAK ALWAYS REPLACE BOTH PADS AND MAKE SURE THAT THEY ARE CORRECTLY POSITIONED IN THE CALLIPER BRAK SYS 157 Braking system SCARABEO 50 4T 4V Characteristic Friction material minimum thickness 1 5 CAUTION ALWAYS REPLACE BOTH PADS AND MAKE SURE THEY ARE CORRECTLY POSITIONED INSIDE THE CALLIPER Refitting Check friction material for appropriate thickness If thinner than the minimum value replace it In case of uneven wear replace the brake pads when the friction material thickness difference is 0 5 mm 0 2 inc 0 5 mm oo 1 If the anti friction plates 6 are worn replace them Fit two new pads 7 together with the anti friction plates Insert the spring 5 correctly Fit cylinder 4 Fit circlips 3 Fit the brake calliper cover 1 Check the brake fluid Fit two new pads 7 together with the anti friction plates 6 Insert the spring 5 correctly Fi
39. HE CAMSHAFT IT IS ESSENTIAL TO FIT A NEW BEARING Specific tooling 020450Y Tool for fitting removing the camshaft 004499Y Shaft bearing extractor 004499Y001 Bell for bearing extractor 004499Y002 Screw for bearing extractor 004499Y006 Ring for bearing extractor 004499Y027 part for the bearing extractor ENG 105 Engine SCARABEO 50 4T 4V Removing the cylinder head Remove the cooling covers timing system con trol camshaft and rocking levers Remove the spark plug Remove the 2 side retainers indicated in the fig ure Loosen the 4 head cylinder fixing nuts in two or three stages and in a criss cross sequence Remove the head the 2 alignment dowels and the gasket NOTE IF NEEDED THE HEAD MAY BE REMOVED WITH THE CAMSHAFT PINS AND ROCKING LEVERS WITHOUT RE MOVING THE DRIVING PULLEY UNIT REMEMBER TO HOLD THE TIMING CHAIN WITH A PIECE OF METAL WIRE AND ADJUST THE CHAIN TIGHTENER UPON REFITTING Removing the valves Using the appropriate tool equipped with the component in the figure remove the cotters wash ers and springs of the valves Remove the oil seals with the specific tool Specific tooling 020431Y Valve oil seal extractor 020382Y Tool for removing valve cotters fitted with part 012 ENG 106 SCARABEO 50 4T 4V Engine Removing the cylinder piston assy Remove the cylinder paying attention to the 2 cylinder alignment dowels on the crankcase Remove the gas
40. HE MULTIMETER MUST BE SELECTED TO DETECT CONTINUOUS VOLTAGE Electric characteristic Pick Up voltage value Pick Up voltage value 2 Volt ELE SYS 68 SCARABEO 50 4T 4V Electrical system HV coil With the electronic starter and the HV coil connec ted to the system measure the voltage of the coil primary during the start up test with the voltage peak adaptor and by connecting the positive ter minal to the ground lead and the negative terminal to the coil positive connector Replace the control unit if non conforming values selots elele rge zv are measured THE POSITIVE TERMINAL OF THE HV COIL PRIMARY IS BLACK Electric characteristic Coil voltage value high voltage Coil voltage value high voltage gt 100 Volt Stator check Using a tester check the resistance between the brown ground and black ground terminal NOTE THE VALUES ARE STATED AT AMBIENT TEMPERATURE A CHECK WITH THE STATOR AT OPERATING TEMPERA TURE MAY RESULT IN VALUES HIGHER THAN THOSE STATED Electric characteristic Stator Brown ground 170 O Pick Up Stator Black ground 1 O Stator Voltage regulator check A malfunction in the voltage regulator may cause the following problems depending on the type of failure 1 Bulbs burned out regulator in short circuit 2 Malfunction of the lighting system and the electric starter regulator interrupted 3 Battery not recharging 4 Turn indicators not w
41. IN THE MASSES MUST SHOW A CEN TRAL FAYING SURFACE AND MUST NOT BE DIFFERENT FROM ONE ANOTHER DIFFERENT CONDITIONS MAY CAUSE CLUTCH TEARING CAUTION DO NOT OPEN THE MASSES USING TOOLS SO AS TO PREVENT A VARIATION IN THE RETURN SPRING LOAD Characteristic Minimum thickness allowed 1 mm Refitting the clutch Pre assemble the driven pulley unit with spring sheath and clutch Position the spring with the sheath Fit the components to the tool and preload the spring being careful not to damage the plastic sheath and the end of the threaded shank ENG 90 SCARABEO 50 4T 4V Engine Refit the clutch lock nut and tighten to the pre scribed torque CAUTION USE A BOX SPANNER WITH SMALL CHAMFER SO AS NOT TO DAMAGE THE CLUTCH NUT CAUTION POSITION THE NON CHAMFERED SURFACE OF THE NUT IN CONTACT WITH THE CLUTCH Locking torques N m Clutch nut 55 60 Refitting the driven pulley Refit the driven pulley assembly clutch bell and nut using the specific tool Specific tooling 020565Y Flywheel lock calliper spanner Locking torques N m Driven pulley shaft nut 40 44 Nm Drive belt Make sure the driving belt is not damaged and does not have cracks in the toothed grooves Check belt for correct width Characteristic Driving belt Minimum width 17 5 mm ENG 91 Engine SCARABEO 50 4T 4V Removing the driving pulley Lock the driving pulley using the specific t
42. ITION ADVANCE SUCH AS TO CAUSE PINKING HEAD KNOCKING ETC Specific tooling 020565Y Flywheel lock calliper spanner Locking torques N m Flywheel nut 52 58 ENG 102 SCARABEO 50 4T 4V Engine Refitting the starter motor Install the starter motor in its position in the crank case Tighten the screw on the head side but do not lock it screw the other screw fitting the black ground lead Then tighten the 2 screws to the pre scribed torque Tighten the red positive lead fixing screw on the side contact NOTE REFIT THE REMAINING PARTS AS DESCRIBED IN THE CHAPTERS ON CYLINDER HEAD TIMING SYSTEM LU BRICATION FLYWHEEL AND TRANSMISSION Locking torques N m Starter motor screws 11 13 Cylinder assy and timing system Removing the rocker arms cover Remove the cooling covers Remove the 4 tappet cover retainers Remove the cover plus the O Ring Remove the 3 screws and then remove the Blow by cover Clean the nozzle labyrinth and the membrane replace it if required then refit the unit to the cover ENG 103 Engine SCARABEO 50 4T 4V Removing the timing system drive First loosen the tensioner central screw and then remove it together with the spring Unscrew the 2 retainers indicated in the figure and remove the chain tightener support being careful to collect the sealing gasket NOTE SHOULD THE GASKET NOT BE IN GOOD CONDITIONS CLEANING THE FAYING S
43. NG UP KEEP THE FLUID LEVEL IN THE RES ERVOIR PARALLEL TO THE RESERVOIR EDGE AND DO NOT SHAKE THE VEHICLE Remove the gasket 5 NOTE TO REACH THE MAXIMUM LEVEL TOP UP UNTIL THE SIGHT GLASS IS FULLY COVERED BUT LEAVE A 5 6 MM 0 20 0 23 IN MARGIN FROM THE RESERVOIR EDGE CAUTION LN DO NOT EXCEED THE MAX LEVEL REFERENCE MARK WHEN TOPPING UP TOP UP TO THE MAX LEVEL REF ERENCE MARK ONLY WHEN NEW PADS ARE FITTED WARNING MAIN 50 SCARABEO 50 4T 4V Maintenance NEVER FILL THE RESERVOIR UP TO THE MAX LEVEL REFERENCE MARK IF THE PADS ARE WORN THIS WOULD CAUSE THE FLUID TO LEAK OUT FROM THE RESERVOIR WHEN THE NEW PADS ARE FITTED USE ONLY THE RECOMMENDED PRODUCT FROM CLEAN AND SEALED CONTAINERS NEVER REUSE OLD BRAKE FLUID Top up the reservoir with brake fluid up STOPI to the MAX level MAX LEVEL ab sine LEAVE 0 20 0 23 in OK LEVE J e Refit gasket 5 correctly in its posi 5 6 mm tion Refit cover guide 4 correctly in its position Refit cover 2 Insert and tighten the two screws 1 a 3 SY e Hefit the front handlebar cover CAUTION AFTER SERVICING BRAKES ALWAYS CHECK THAT THEY OPERATE PROPERLY EXCESSIVE BRAKE LEVER CLEARANCE OR POOR BRAKING PERFORMANCE MAY INDICATE THAT CIRCUIT NEEDS PURGING THIS MAY ALSO BE DUE TO ANY OTHER PROBLEM IN THE BRAK ING SYSTEM Headlight adjustment AON 32 81 ft 10 m LN NEVER USE THE VEHICLE IF THE HEADLAMPS D
44. NOT CAGED AND THEY AUTOMATICALLY FALL WHEN THE FORK IS REMOVED Remove the fork from the steering tube Remove the inside ring 8 and the balls 9 from the upper bearing 10 Remove the inside ring 11 and the balls 12 from the lower bearing 13 Wash all the bearing parts thoroughly including the outside rings 14 and 15 Check all the parts for wear and remove them if necessary Put a large quantity of grease on all the bearing parts holding the balls in their position on the outside ring with the grease before trying to fit the fork following the procedure above SUSP 149 Suspensions CAUTION WHEN REFITTING PAY ATTENTION TO THE AMOUNT OF BALLS TO BE FITTED Rear 21 BALLS 10 FOR THE UPPER BEARING 11 25 BALLS 13 FOR THE LOWER BEARING 14 Removing the rear wheel NOTE Hemove the silencer Deflate the rear wheel completely SCARABEO 50 4T 4V TO UNSCREW THE WHEEL NUT 1 IT IS NECESSARY TO LOCK THE WHEEL ROTATION NOTE Pull the rear brake lever 2 complete ly then place a small piece of card board 3 on the handle and keep the brake lever pulled by using a clamp 4d Remove the cover 5 Unscrew and remove nut 1 and the washer Take out the wheel SUSP 150 r4 amp Po A we Ke AA CS Fa eet Ox SU des 7 if Wf SCARABEO 50 4T 4V Suspensions WHEN REFITTING USE A NUT FOR EACH NEW WHEEL DO NO
45. NTERING THE BRAKE SYSTEM When the brake fluid that comes out is homogeneous without bubbles it means air has successfully been eliminated from the system Close the bleed plug 2 accurately and tighten it correctly NOTE REPEAT THE LAST TWO OPERATIONS UNTIL THE BUBBLES ARE TOTALLY ELIMINATED BRAK SYS 159 Braking system SCARABEO 50 4T 4V Reposition the protection cap 1 on MAX LEVELI the bleeder spout 2 LEAVE 0 20 0 23 in e Check the brake fluid CAUTION AFTER REFITTING PULL THE BRAKE LEVER REPEAT EDLY AND CHECK THAT THE BRAKING SYSTEM OPER ATES CORRECTLY CAUTION PAY ATTENTION TO THE DISC AND THE FRICTION MA TERIAL MAKING SURE THEY ARE NOT DIRTY OR GREASED SPECIALLY AFTER MAINTENANCE OPERA TIONS OR INSPECTION Rear drum brake After removing the silencer and the rear wheel operate as follows Remove the shoe spring using the spe cific tool Remove the shoe with a lever Refit the new shoe by slightly hitting with the mallet Fix the spring with the specific tool Adjusting the drum brake Adjust the measure point of the rear drum brake operating the set screw shown in the figure With the brake lever released the wheel should rotate freely BRAK SYS 160 INDEX OF TOPICS Cassis CHAS Chassis SCARABEO 50 4T 4V Seat Saddle removal Remove the pin and slide off the bolt e Undo and remove the 4 screws Removing the saddle
46. O NOT WORK PROPERLY NEVER USE THE VEHICLE IF THE HEADLAMPS ARE NOT CORRECTLY ADJUSTED YOU MAY DAZZLE THE VEHI CLE RIDING TOWARDS YOUR DIRECTION THIS MAY AL SO REDUCE THE POSSIBILITY OF SEEING AN OBSTACLE AHEAD OF YOU ON THE ROAD WHEN RIDING AT NIGHT IT IS ALWAYS ADVISABLE TO REDUCE SPEED WHEN RIDING AT NIGHT SO AS TO HAVE ENOUGH TIME TO AVOID POTENTIAL OBSTACLES AND TO ADAPT YOUR SELF TO LOW VISIBILITY CONDITIONS RESULTING FROM DARKNESS FAILURE TO OBSERVE THESE RECOMMENDATIONS MAY CAUSE A CRASHINTO ANOTHER VEHICLE RESULT ING IN SERIOUS INJURIES OR EVEN DEATH NOTE THE PROCEDURE DESCRIBED HEREIN COMPLIES WITH THE ITALIAN STANDARDS REGARDING MAXIMUM HEIGHT OF THE LIGHT BEAM IF THE VEHICLE IS USED IN OTHER COUNTRIES NA TIONAL REGULATIONS MUST BE OBSERVED MAIN 51 Maintenance SCARABEO 50 4T 4V For a quick check on correct light beam direction place the scooter on level ground 10 m 32 81 ft from a wall Turn on the low beam light sit on the scooter and check that the light beam projected to the wall is a little below the headlight horizontal straight line about 9 10 of the total height To adjust the light beam Adjust screw 2 using a screwdriver Turn the screwdriver clockwise to lift the light beam Turn the screwdriver anticlockwise to lower the light beam SAS filters inspection and cleaning Loosen and remove the three screws B the cover of the secondary air housing and
47. RECTLY ON THE ALUMINIUM OF THE HEAD Characteristic Standard height Intake 24 397 mm Standard height Exhaust 23 996 mm Fitting clearance Maximum axial clearance allowed 0 5 mm D kii IS S S Check the outside diameter of the rocker pins Check there are no signs of wear or scoring on the rocker pins Check the internal diameter of each rocker arm Check that the pad in contact with the cam is not worn DIAMETER OF PINS AND ROCKING LEVERS Specification Desc Quantity Rocking lever inner diameter 11 015 11 035 mm Rocking lever pin diameter 10 977 10 985 mm CHAR 28 SCARABEO 50 4T 4V Characteristics Products TABELLA PRODOTTI CONSIGLIATI Product Description Specifications AGIP CITY HI TEC 4T Engine oil SAE 5W 40 APISL ACEA A3 JASO MA AGIP GEAR SYNTH SAE 75W 90 Gearbox oil API GL4 GL5 AGIP FORK 7 5W Fork oil AGIP GREASE SM2 Lithium grease with molybdenum for NLGI 2 bearings and other points needing lubri cation AGIP BRAKE 4 Brake fluid FMVSS DOT4 AGIP FILTER OIL Oil for air filter soonge E CHAR 29 INDEX OF TOPICS Toora TOOL SCARABEO 50 4T 4V Stores code 001467Y008 001467Y029 004499Y 005095Y 008119Y009 020004Y Tooling TOOLS Description Calliper to extract 17 mm diameter bear ings Bell for 38 mm outside diameter bearings Bearing extractor Equipped with 1 Bell 2 Sleeve 3 Screw 6 Ring 27 Half rings 34 Half rings Engine sup
48. S Ar orange Az sky blue B blue Bi white G yellow Gr grey Electrical system ELE SYS 55 Electrical system M brown N black R red V green Vi purple Ro pink Components arrangement SCARABEO 50 4T 4V KEY 1 Voltage regulator 2 Left light switch 3 Horn 4 Left front turn indicator RY10W 12V 5 Rear brake stop light switch 6 Battery 7 Fuses 8 Left rear turn indicator bulb RY10W 12V 9 Spark plug 10 Rear tail stop light bulb 11 High low beam bulb 35 35W 12V 12 Control unit 13 Diagnostics socket ELE SYS 56 SCARABEO 50 4T 4V Electrical system 14 Solenoid 15 Starter motor KEY 16 Start up relay 17 High voltage coil 18 Pick up 19 Turn indicators 20 Right front turn indicator RY10W 12V 21 Key switch 22 Front brake stop light switch 23 Instrument panel 24 Fuel level sensor 25 Right rear turn indicator bulb RY10W 12V 26 Alternator 27 Right light switch ELE SYS 57 Electrical system SCARABEO 50 4T 4V Ground points Ground point on engine Remove the tail fairing to reach it Ground point on chassis e Remove the footrests to reach it Electrical system installation Motorcycle division The wiring distribution is subdivided in two essential sections as indicated in the figure ELE SYS 58 SCARABEO 50 4T 4V 1 Front section 2 Rear section Front side A Cable harness routing to the steering area 1
49. T REFIT THE SCOOTER WITH THE OLD NUT THIS IS A SPECIAL TYPE OF NUT Locking torques N m Nut tightening power 1 110 Nm 79 56 ftlb Swing arm Removal The worn or damaged bushings on the rubber insulator may cause an annoying vibration and an unsafe manoeuvrability To check if the bushings are in good conditions it is necessary to remove the engine support axle Remove the lower shield Remove the engine CAUTION ONCE THE BUSHINGS ARE REMOVED HOLD THE CHASSIS WITH A SUPPORT 1 Place a support of suitable height under the chas sis central part CAUTION MAKE SURE THE SCOOTER IS STABLE AND FIRM Remove the nut 2 and take out the tightening pin 3 fixing the chassis to the rod on the opposite side e Remove the inside rod 4 Check if the silent block 5 and the buffer 6 are in good conditions and replace them if damaged Locking torques N m Frame pin rod locking torques 25 Nm 18 08 ftlb SUSP 151 Suspensions SCARABEO 50 4T 4V Overhaul Periodically check the pin fulcrum engine and bearings clearance To carry out these operations proceed as follows Park the vehicle on its centre stand Hold the wheel firmly and try to move it perpendicularly into the stroke direc tion If there is any clearance check all the retainers that connect the support Shock absorbers SUSP 152 SCARABEO 50 4T 4V Suspensions Removal e Park
50. TING THAT IS SLIPPERY DRIVE CAREFULLY FOR THE FIRST FEW KILOMETRES MILES NEVER USE RUBBER TREATMENT AGENTS OF ANY KIND ON THE TYRES IN PARTICULAR ENSURE THAT THE TYRES DO NOT COME INTO CONTACT WITH LIQUID FUEL THAT WOULD CAUSE A RAPID DETERIORATION OF THE RUBBER A TYRE THAT HAS BEEN IN CONTACT WITH OIL OR PETROL MUST BE REPLACED AND NOT SIMPLY CLEANED DO NOT FIT TYRES WITH INNER TUBES ON WHEEL RIMS FOR TUBELESS TYRES AND VICE VERSA DISC BRAKE CAUTION ANY OIL OR OTHER LIQUIDS ON A DISC WILL SOIL THE BRAKE PADS SOILED PADS MUST BE REMOVED AND REPLACED A SOILED DISC OR A DISC WITH TRACES OF OIL MUST BE CLEANED WITH A TOP QUALITY DEGREASING AGENT IF THE VEHICLE IS USED CLOSE TO WATER OR ON DUSTY OR UNSURFACED ROADS OR IF IT IS USED FOR SPORTS APPLICATION HALVE THE SERVICE INTERVALS BRAKE FLUID CAUTION DO NOT USE FLUIDS OTHER THAN THOSE PRESCRIBED AND DO NOT MIX 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 IN THE PLAY OR ELASTIC RESISTANCE IN THE BRAKE LEVERS ARE DUE TO FAULTS IN THE HYDRAULIC CIRCUIT MAKE ESPECIALLY SURE THAT BRAKE DISCS AND THE FRICTION MATERIAL ARE NOT SMEARED OR GREASY PARTICULARLY AFTER CARRYING OUT MAINTENANCE AND IN SPECTION OPERATIONS CHECK THAT BRAKE WIRES ARE NOT TWISTED OR WORN ENSURE THAT WATER OR DUST DO NOT INGRESS INADVERTENTLY IN
51. TO THE CIRCUIT IT IS ADVISABLE TO WEAR LATEX GLOVES WHEN SERVICING THE HYDRAULIC CIRCUIT CHAR 8 SCARABEO 50 4T 4V Characteristics 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 VEHICLE 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 ELECTRIC CONNECTORS Electric connectors must be disconnected as described below failure to comply with this procedure causes irreparable damage to both the connector and the wiring harness Press the relative safety clips if applicable CAUTION DO NOT DISCONNECT CONNECTORS BY PULLING THE CABLES Grip the connectors and disconnect them by pulling them in opposite directions In presence of dirt rust humidity etc clean the connector s internal parts carefully using a pressurised air jet Ensure that the cables are correctly fastened to the intern
52. URFACES THOROUGHLY TO AVOID ENGINE OIL LEAKS AND REPLACE THE GASKET Remove the driving pulley Remove the oil pump chain Remove the tappet cover Remove the central screw and the belleville washer indicated in the figure lock the camshaft sprocket with the specific tool NOTE TO FACILITATE REMOVING THE HEAD COMPONENTS SET THE CRANKSHAFT TO THE TIMING POINT TDC OF THE COMPRESSION END Specific tooling 020565Y Flywheel lock calliper spanner Remove the camshaft control pulley and the shim washer below Remove the pinion of the crankshaft timing system control To remove the chain lower guiding pad remove it from the head by pulling upwards NOTE IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO ENSURE THAT THE DIRECTION OF RO TATION IS MAINTAINED See also ENG 104 SCARABEO 50 4T 4V Engine Removing the cam shaft Remove the rocking lever pin clamping screw in dicated in the figure Remove the Seeger ring clamping the camshaft bearing Remove the pins and the rocking levers Remove the calibrated pads NOTE MARK THE ROCKING LEVERS FITTING POSITION IN OR DER TO AVOID MISPLACING THE INTAKE AND EXHAUST ENDS Remove the camshaft and the bearing using the specific tool shown in the figure Take out the camshaft bearing with the aid of the specific tool being careful to mount one screw on the camshaft in order to protect the camshaft thread NOTE IF A BEARING DETACHES FROM T
53. UTION SUSP 145 Suspensions SCARABEO 50 4T 4V WHEN REMOVING THE FORK PAY ATTENTION TO COLLECT ALL THE BALLS OF THE FORK BEARINGS THE BALLS ARE NOT CAGED AND THEY AUTOMATICALLY FALL WHEN THE FORK IS REMOVED Removing the sleeves NOTE THE SLEEVES CAN BE REMOVED FROM THE FORK EVEN IF IT IS INSTALLED IN THE VEHICLE Remove the front wheel To remove the right sleeve from the fork e Remove the screw 3 Take out the sleeve Check the sealing ring wear 5 and replace it if necessary Locking torques N m Screw tightening power 3 24 Nm 17 36 ftlb To remove the left sleeve from the fork e Remove the nut 6 Take out the sleeve Check the sealing ring wear 7 and replace it if necessary Locking torques N m Screws tightening power 6 24 Nm 17 36 ftlb Removing the complete shock absorber Only the left sleeve of the fork has a shock ab ia sorber 8 The shock absorber can be removed also when xx the fork is fitted on the scooter Remove the left sleeve of the fork Remove the front case Turn the handlebar completely clock wise to the right Prevent the screw 9 from rotating with a suitable wrench Unscrew and remove the nut 10 Take out the entire shock absorber 8 SUSP 146 SCARABEO 50 4T 4V Suspensions NOTE UPON REFITTING PLACE THE NUT 10 CORRECTLY Steering bearing Checking bearing clearance To check the
54. VEN TINY AMOUNTS OF BATTERY ACID MAY CAUSE BLINDNESS IF IT COMES INTO CONTACT WITH THE EYES 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 CHAR 6 SCARABEO 50 4T 4V Characteristics LN KEEP OUT OF THE REACH OF CHILDREN CAUTION uN 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 FUEL CAUTION LN 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 The engine and the components of the exhaust system can get very hot and re
55. VES AND THAT BETWEEN THE PISTON AND THE CYLINDER ARE AS SPECIFIED IN ANY CASE NEW PISTON SEALING RINGS USED IN COMBI NATION WITH A USED CYLINDER MAY HAVE DIFFERENT BEDDING CONDITIONS THAN THE STANDARD ONES ENG 109 Engine SCARABEO 50 4T 4V SEALING RINGS Name Description Dimensions Initials Quantity 1st Compression ring 39 x 1 A 0 08 0 20 2nd Compression ring 39 x 1 A 0 05 0 20 Oil scraper ring 39 x2 A 0 20 0 70 1st Compression ring 39 2 x 1 A 0 08 0 20 1st Oversize 2nd Compression ring 39 2 x 1 A 0 05 0 20 1st Oversize Oil scraper ring 1st 39 2x2 A 0 20 0 70 Oversize 1st Compression ring 39 4 x 1 A 0 08 0 20 2nd Oversize 2nd Compression ring 39 4 x 1 A 0 05 0 20 2nd Oversize Oil scraper ring 2nd 39 4 x 2 A 0 20 0 70 Oversize 1st Compression ring 39 6 x 1 A 0 08 0 20 3rd Oversize 2nd Compression ring 39 6 x 1 A 0 05 0 20 3rd Oversize Oil scraper ring 3rd 39 6 x 2 A 0 20 0 70 Oversize Removing the piston Install piston and pin onto the connecting rod with the piston arrow aligned facing the exhaust Fit the pin retainer ring on the appropriate tool Specific tooling 020448Y Tool for fitting the pin snap rings ENG 110 SCARABEO 50 4T 4V Engine With the opening in the position indicated on the tool set the retainer ring into position in the tool with the punch Rest the tool on the piston paying attention that the 90 chamfered side faces upwards as shown in the figur
56. al connector terminals NOTE THE CONNECTORS CAN ONLY BE CONNECTED IN ONE DIRECTION CONNECT THEM THE RIGHT WAY ROUND Then connect the connectors ensuring that they couple correctly if fitted with the specific clips you will hear them click into place BEFORE REMOVING COMPONENTS Before disassembling components remove dirt mud dust and foreign bodies from the ve hicle Use the special tools designed for this vehicle as required COMPONENTS REMOVAL Do not loosen and or tighten screws and nuts using pliers or any other tools than the specific wrench Mark the positions on all connection joints pipes cables etc before separating them and identify them with different distinctive symbols CHAR 9 Characteristics SCARABEO 50 4T 4V Each component needs to be clearly marked to enable identification during reassembly e Clean and wash the dismantled components carefully using a low flammability detergent Keep coupled parts together since they have adjusted to each other due to normal wear and tear e 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 INSTALLE
57. alve head and rotating it on the V shaped support Characteristic Limit allowed 0 03 mm Check the deviation of the valve stem by resting iton a V shaped support and measuring the ex tent of the deformation using a dial gauge Characteristic Limit value allowed 0 1 mm Inspecting the valve stem guide clearance Measure the valve guides VALVE GUIDE DIAMETER Specification Desc Quantity Valve guide Standard diameter 4 0 012 mm Valve guide Maximum diameter allowed 4 0 022 mm ENG 115 Engine SCARABEO 50 4T 4V After measuring the valve guide diameter and the valve stem diameter check the clearance be tween guide and stem Specification INTAKE Desc Quantity 0 015 0 042 mm o Standardcdeaanee 1 1 1 1 1 0 015 0042mm 1 1 10 Limit allowed Specification Standard clearance Limit allowed Refitting the valves Lubricate the valve guides with graphite grease Place the valve springs lower washers on the head Using the punch alternately fit the 4 sealing rings EXHAUST 0 06 mm Desc Quantity 0 025 0 052 mm 0 07 mm Fit the valves springs and upper washers Using the appropriate tool compress the springs and fit the cotters in their seats ENG 116 SCARABEO 50 4T 4V Engine Inspecting the cam shaft Check the camshaft bearings for signs of abnor mal wear Characteristic Standard diameter Bearing
58. aterial The masses must exhibit no traces of lubricants in that case check the driven pulley unit seals NOTE UPON RUNNING IN THE MASSES MUST EXHIBIT A CEN TRAL FAYING SURFACE AND MUST NOT BE DIFFERENT FROM ONE ANOTHER DIFFERENT CONDITIONS MAY CAUSE CLUTCH TEAR ING CAUTION DO NOT USE TOOLS TO OPEN THE MASSES TO AVOID VARIATION IN THE RETURN SPRING LOAD Characteristic Check minimum thickness 1 mm Removing the clutch Equip the tool with long pins screwed from out side into position A fit the driven pulley assem bly to the tool and have the central screw make contact CAUTION THE TOOL WILL GET DEFORMED IF THE CENTRAL SCREW IS TIGHTENED IN EXCESS ENG 86 SCARABEO 50 4T 4V Engine Use a 34 mm box spanner to remove the clutch locking nut Loosen the central screw by releasing the spring of the driven pulley assembly Separate the components Specific tooling 020444Y Tool for fitting removing the clutch on the driven pulley Pin retaining collar Remove the collar with the aid of 2 screwdrivers Remove the 3 guide pins and the movable half pulley Removing the driven half pulley bearing Remove the roller bearing with the special ex tractor fitted on the lower side of the fixed half pulley CAUTION POSITION THE HOLDING EDGE OF THE EXTRACTION PLI ERS BETWEEN THE END OF THE BEARING AND THE BUILT IN SEALING RING Specific tooling 001467Y
59. attery charge selector to the type of battery that requires recharging that is at a current equal to 1 10 of the battery rated capacity Connections to the power supply source must be implemented by connecting corre sponding poles to and to The battery should always be kept clean especially its top side and the terminals should be coated with petroleum Jelly ELE SYS 76 SCARABEO 50 4T 4V Electrical system CAUTION N LN NEVER USE FUSES WITH A CAPACITY 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 HARMFUL TO THE BAT TERY CONSEQUENTLY ONLY USE DISTILLED WATER CAUTION TO ENSURE MAXIMUM PERFORMANCE THE BATTERY MUST BE CHARGED BEFORE USE INADEQUATE CHARGING OF THE BATTERY BEFORE BEING PUT INTO OPERATION SHORT ENS BATTERY LIFE Connectors ELECTRONIC STARTER SECTION A B A 1 HV COIL CONTROL al laa lt I3 co 2 KEY SWITCH CONTACTS TO GROUND 5 3 HV COIL POSITIVE E L ee ee SECTION B 1 KEY POSITIVE STARTER POWER SUPPLY PICK UP SIGNAL GROUND SOLENOID VALVE NTC TEMPERATURE SENSOR LIGHT REMOTE CONTROL DIAGNOSIS SOCKET ON OOK WO D ELE SYS 77 Electrical system SCARABEO 50 4T 4V Voltage regulator 1 LIGHTING SYSTEM POWER SUPPLY al ternating GROUND BATTERY POSITIVE FROM FLYWH
60. cteristic Pick up resistance approximately 170 Ohm HV primary coil check Disconnect the electronic starter connector and check continuity between terminal No 3 White Purple and terminal No 1 Black White see fig ure If non conforming values are measured check 1 2 3 4 5 6 7 8 again the HV primary coil directly on the positive N Bi Bi Vi and negative terminals If the values are correct repair the cable harness or reset the connections otherwise replace the HV coil Electric characteristic HV primary coil resistance ELE SYS 67 Electrical system SCARABEO 50 4T 4V 0 5 0 6 ohm HV secondary coil check Disconnect the spark plug cap from the HV cable and measure the resistance between the HV cable terminal and the HV coil negative terminal see figure If non conforming values are measured replace the HV coil To carry out a more complete diagnosis check the peak voltage with the multimeter adaptor Specific tooling 020409Y Multimeter adaptor Peak voltage detection Electric characteristic HV secondary coil resistance 3000 3600 ohm Pick up Disconnect the ECU connector and connect the positive terminal to connector No 3 Brown and the negative terminal to connector No 4 Blue Use the start up system to run the engine and measure the voltage produced by the Pick Up Replace the Pick Up if non conforming values are J j1 2 3 4 5 6 7 8 M B measured NOTE T
61. e Fit the pin snap ring using the pin CAUTION USING A MALLET TO SET THE RINGS IN POSITION MAY DAMAGE THE RING SEATS Refitting the piston rings Fit the oil scraper ring starting from the spring making sure that the spring ends do not overlap Fit the two piston rings so that their openings and that of the oil scraper ring are never aligned Fit the 2nd piston ring with the identification letter T facing the piston crown Fit the 1st piston ring with the identification letter T facing the piston crown Offset the piston ring openings by 120 as shown in the figure Lubricate the components with engine oil NOTE TO OBTAIN A BETTER BEDDING THE 2 SEALING RINGS HAVE BEEN MADE WITH A CONICAL CONTACT SECTION WITH THE CYLINDER FOR THIS REASON IT IS IMPOR TANT TO RESPECT THE INSTRUCTIONS TO FIT THE RINGS WITH THE T MARK FACING UPWARDS ENG 111 Engine SCARABEO 50 4T 4V Refitting the cylinder Fit the cylinder base gasket Fit the cylinder as shown in the figure The piston can be kept out of the crankcase plane geme we IN using the appropriate tool wt NOTE BEFORE FITTING THE CYLINDER CAREFULLY BLOW AIR INTO THE LUBRICATION DUCT AND LUBRICATE THE CYLINDER LINER Specific tooling 020288Y Fork for fitting the piston on the cyl inder Should the four cylinder stud bolts be replaced in this kind of engine it is necessary to tighten the head nuts strictly following the pr
62. e wheel axle Place the wheel between the fork rods Place the speedometer transmission by inserting the tongue in its seat on the wheel hub CAUTION SUSP 144 SCARABEO 50 4T 4V Suspensions WHEN REFITTING THE WHEEL PAY ATTENTION NOT TO DAMAGE THE BRAKE CABLE THE DISCS AND THE PADS Fit the wheel between the fork rods carefully inserting the disc into the brake calliper Turn the wheel until the holes on the K vs axle and the bearings are not aligned Fit the washer 6 between the speed ometer transmission 5 and right fork rod Push it completely into the axle 4 and tighten it with the appropriate tight ening power Locking torques N m Front wheel spindle nut 35 Nm 25 81 ftlb Tighten the axle fixing screws 3 Locking torques N m Screw tightening power 3 12 Nm 8 68 ftlb Front fork Removal CAUTION PLACE AN APPROPRIATE SUPPORT UNDER THE SCOOTER TO PREVENT IT FROM FALLING e Park the vehicle on its centre stand e Hemove the wheel CAUTION DO NOT FORCE THE CABLES THE TUBES THE WIRES OR THE ELECTRICAL CONNECTORS Remove the handlebar completely i DN e nn Hold the handlebar so that it does not put weight on the electrical wires and cables Slide off and remove the rubber gasket 5 Unscrew and remove the tightening nut 6 Unscrew and remove the adjustment nut Remove the fork from the steering tube CA
63. embling 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 VEHICLE PARTS WITH YOUR MOUTH VEHICLE 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 LN EXHAUST EMISSIONS CONTAIN CARBON MONOXIDE A POISONOUS GAS WHICH CAN CAUSE LOSS OF CONSCIOUSNESS AND EVEN DEATH HYDROGEN GAS AND BATTERY ELECTROLYTE CAUTION THE BATTERY ELECTROLYTE IS TOXIC CORROSIVE AND ASIT 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 E
64. en the other two terminals 87 30 Electric characteristic Correct value with the relay powered 00 Correct value with the relay not powered eo Q Power the motor directly with a direct voltage of 12 20 25A V The motor must turn and make the engine rotate AMPEROMETRO using a 20 25 A current 12 V VOLTMETRO W MOTORING If the motor does not turn check the brushes and OMIANENTO BATTERIA remove them if required ELE SYS 72 SCARABEO 50 4T 4V Electrical system Turn signals system check 4 TURN INDICATORS NOT WORKING If the turn indicators do not work do the following Remove the regulator connector and place the tester probes between terminal 3 Green Orange and terminal 2 Black Turn the key switch to ON and check that there is voltage on battery If no voltage is detected re peat the test now between the orange cable and the ground lead If there is no voltage even after this operation check the cable harness and the contacts of the key switch and the battery Con versely if battery voltage is detected black cable check the regulator ground cable harness Ifthe above tests have positive results jump con B N tacts 5 Blue Back and 3 Green Orange on the 12V connector set the key switch to ON and turn the Key ewitcn turn indicator switch to the left and right to see when the lights are steadily on as they are directly powered by the ba
65. en to the prescribed torque and check the tensioner pad moves adequately Fit the timing system pinion to the crankshaft with the chamfered side facing the insertion towards the main bearing Loop the timing chain around the sprocket on the crankshaft Locking torques N m Chain tensioner pad screw 5 7 Nm Refit the spacer on the camshaft Rotate the engine so that the piston Is at top dead centre using the reference marks on the flywheel and the crankcase While doing so fit the chain on the camshaft con trol pulley and make the reference notch coincide with the point on the head Fit the pulley on the camshaft Fit the belleville washer so that the outer rim touches the pulley ENG 119 Engine SCARABEO 50 4T 4V Draw the screw closer but without reaching its final locking point Push the tensioner pad slightly to check the cor rect timing i Em TX M Use the specific tool to lock the camshaft sprock et gear and tighten the screw E A l e 0p Adjust valve clearance E Replace the O Ring on the tappet cover ry Fit the tappet cover and lock it with the 4 fixing a screws shown in the figure Specific tooling 020565Y Flywheel lock calliper spanner Locking torques N m Camshaft pulley screw 12 14 Head cover screw 8 10 Nm Set the tensioner slider to its home position Fit the chain tensioner on the cylinder using a ne
66. ess ENG 100 SCARABEO 50 4T 4V Engine Removing the flywheel magneto Lock the flywheel rotation using the calliper span ner Remove the nut CAUTION USING A CALLIPER SPANNER OTHER THAN THE ONE SUPPLIED COULD DAMAGE THE STATOR COILS Take out the flywheel with the extractor Specific tooling 020565Y Flywheel lock calliper spanner 020162Y Flywheel extractor Inspecting the flywheel components Check that the flywheel internal magnetos are in good conditions Check that the flywheel riveted joints are correctly tightened Check there are no deformations that may cause rubbing on the stator and the Pick Up Check that the stator winding its ferromagnetic support and the pick up are in good conditions ENG 101 Engine SCARABEO 50 4T 4V Starter gear rim Check the toothing is level and in good conditions Intermediate gear Check that the keying toothing on the sprocket and the starter motor are in good conditions Check that the Bendix opens and returns ade quately Refitting the flywheel magneto Refit the stator and the pick up being careful to thread the wirings through the appropriate crank case couplings Refit the flywheel on the crankshaft being careful to respect the keying then lock rotation with the specific tool and tighten the nut to the prescribed torque NOTE A VARIATION IN THE AIR GAP DISTANCE MAY RESULT IN A VARIATION IN THE IGN
67. ews at the crankcase base Remove the 4 side screws Remove the 3 covers Remove the cover sealing gaskets on the head For refitting repeat the removal steps but in re verse order CAUTION TAKE CARE TO CORRECTLY PLACE THE FLYWHEEL CONNECTOR NOTE WHEN REFITTING THE COVER PAY ATTENTION NOT TO DAMAGE THE STATOR ELECTRICAL CABLE HARNESS ENG 98 SCARABEO 50 4T 4V Engine Cooling fan Remove the cooling fan by undoing the 3 screws that fix it to the rotor When refitting the fan pay attention that the screw holes in the fan and the rotor coincide then tighten the screws to the prescribed torque Removing the stator Remove the two Pick Up screws and the 2 stator fixing screws shown in the figure Remove the stator and its cable harness ENG 99 Engine SCARABEO 50 4T 4V Refitting the stator Refit the stator and the flywheel carrying out the removal steps but in reverse order tightening the retainers to the prescribed torque NOTE THE PICK UP WIRE MUST BE POSITIONED ADHERING TO THE FUSION TONGUE ON THE CRANKSHAFT IN SUCH A WAY AS TO AVOID BEING CRUSHED BY THE FAN COVER UNIT Locking torques N m Pick up screws 3 4 Stator screws 3 4 Flywheel and starting Removing the starter motor Undo the two screws on the power positive con tact and disconnect the cable Undo the 2 screws fixing the starter motor to the crankcase and collect the power cable harn
68. front and rear and their warning lights Headlight adjustment according to regulations in force Front and rear stop light switches and their bulbs Turn indicators and their warning lights Instrument panel lights Instrument panel fuel and temperature indicator if present Instrument panel warning lights Horn Electric start up Engine stop via emergency stop switch and side stand Saddle electric opening switch if present PRE DE 175 Pre delivery SCARABEO 50 4T 4V Through the diagnosis tool check that the last mapping version is present in the control unit s and if required program the control unit s again consult the technical service website to know about available upgrades and details regarding the operation CAUTION N TO ENSURE MAXIMUM PERFORMANCE THE BATTERY MUST BE CHARGED BEFORE USE INADEQUATE CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFORE IT IS FIRST USED SHORTENS BATTERY LIFE CAUTION UPON INSTALLING THE BATTERY ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEG ATIVE ONE AND PERFORM THE REVERSE OPERATION UPON REMOVAL WARNING THE BATTERY ELECTROLYTE IS POISONOUS AS IT MAY CAUSE SERIOUS BURNS IT CON TAINS SULPHURIC ACID AVOID CONTACT WITH YOUR EYES SKIN AND CLOTHING IN CASE OF CONTACT WITH YOUR EYES OR SKIN WASH WITH ABUNDANT WATER FOR AP PROX 15 MIN AND SEEK MEDICAL ATTENTION IMMEDIATELY IF ACCIDENTALLY SWALLOWED IMMEDIATELY DRINK LARGE QUANTITIES O
69. he carburettor make sure that the lubrication requirements and valve clearance are met timing is respected the spark plug is in optimum conditions the air filter is clean and sealed and the exhaust system is sealed Connect the multimeter thermometer to the sump using a cap with oil expressly prepared for probes Start the engine and before adjusting the idle speed make sure that the oil temperature is be tween 70 80 C Specific tooling 020331Y Digital multimeter ENG 139 Engine SCARABEO 50 4T 4V Using the rpm indicator of the analyser or a sep arate one adjust the idle screw NOTE THE WASTED SPARK IGNITION SYSTEM OFFERS RE MARKABLE POWER READINGS MAY NOT BE ACCU RATE IF INADEQUATE RPM INDICATORS ARE USED Specific tooling 020332Y Digital rpm indicator Characteristic Engine revs at idle speed 1 800 100 rpm ENG 140 INDEX OF TOPICS Suspensions SCARABEO 50 4T 4V Front Removing the front wheel CAUTION WHEN REMOVING OR REFITTING THE WHEEL PAY SPECIAL ATTENTION NOT TO DAMAGE THE BRAKE CABLE THE DISCS AND THE PADS BEFORE CARRYING OUT THE FOLLOWING OPERATIONS COOL DOWN THE ENGINE AND THE SILENCER TO AMBIENT TEMPERATURE TO AVOID POSSIBLE BURNS e Park the vehicle on its centre stand Place a support under the vehicle so that the wheel can move freely and the vehicle does not fall CAUTION MAKE SURE THE SCOOTER IS STABLE AND FIRM Loosen the axle fixing screw 3
70. he filler cap 2 and the oil drainage plug 1 MAIN 42 SCARABEO 50 4T 4V Maintenance Let the oil drain off completely from the crankcase Tighten drainage plug 1 and pour 100 cm of recommended oll Check the hub oil level Tighten the filler cap 2 CAUTION SCREW THE FILLER CAP AND THE DRAINAGE PLUG TIGHTLY AND MAKE SURE THAT OIL DOES NOT SEEP THROUGH CHECK REGULARLY THAT THERE ARE NO LEAKS IN THE CRANKCASE COVER GASKET RIDING THE VEHICLE WITH INSUFFICIENT LUBRICATION OR CONTAMINATED OR NOT RECOMMENDED LUBRI CANTS ACCELERATES THE WEAR AND TEAR OF MOV ING PARTS AND CAN CAUSE IRRETRIEVABLE DAMAGE Air filter CAUTION CLEAN AND CHECK THE AIR FILTER CONDITIONS MONTHLY OR FOLLOWING THE INDICA TIONS IN THE SCHEDULED MAINTENANCE TABLES THIS WILL DEPEND ON USE CONDI TIONS IF THE VEHICLE IS USED ON DUSTY OR WET ROADS CLEAN AND CHANGE THE FILTER MORE FREQUENTLY To clean the air filter remove it from the vehicle Removing the air filter e Park the vehicle on its centre stand o Undo and remove the six screws 1 MAIN 43 Maintenance SCARABEO 50 4T 4V e Slide off the air filter cover 2 e Slide off the filtering element 3 Cleaning CAUTION DO NOT USE PETROL OR FLAMMABLE SOLVENTS TO CLEAN THE FILTERING ELEMENT TO AVOID RISK OF FIRE OR EXPLOSION Wash the filtering element 3 with clean non inflammable or high volatility solvents and let it dry thoro
71. ibed torque Locking torques N m Engine oil pre filter cap 25 28 Nm Lubrication Crankshaft oil seals Removal Take out the flywheel side oil seal from the crank case being careful not to damage or score the crankcase ENG 125 Engine SCARABEO 50 4T 4V Check that the chain supporting pad is not worn Otherwise replace the pad or fit it in the reverse direction to use the other side Any operation on the chain cover oil seal should be carried out placing the cover on the work table on the covering plate side of the oil pump chain Remove the oil seal with a 30 mm 32 mm Max tube section Refitting Apply engine oil on the oil seal and it seats on the crankcase Operating from the outside and using the specific punch place the oil seal fully down until it reaches the bottom of the seat in the crankcase NOTE FAILURE TO USE THE SPECIFIC TOOL MAY RESULT IN AN INCORRECT DEPTH POSITION AND AS A CONSE QUENCE IN INADEQUATE OIL SEALING Fita new oil seal on the outer rim with the help of the specific tools indicated below Fit a new O ring and lubricate with grease Install the cover on the engine crankcase fit the three screws and place the cover in its seat Tighten the 3 screws to the prescribed torque Specific tooling 020376Y Adapter handle 020358Y 37 x 40 mm adaptor Locking torques N m Timing chain oil pump compartment cover screws 4 5Nm Oil pump
72. in case of excessive wear or damage STANDARD LENGTH OF VALVE Specification Desc Quantity Intake standard length 74 9 mm Exhaust standard length 74 35 mm 4 L T aa m CHAR 25 Characteristics SCARABEO 50 4T 4V Measure the diameter of the valve stem at the E three positions indicated in the diagram Brs STANDARD DIAMETER Specification Desc Quantity Intake 3 970 3 985 mm Exhaust 3 960 3 975 mm MINIMUM DIAMETER ADMITTED Specification Desc Quantity Intake 3 958 mm Exhaust 3 945 mm Calculate the clearance between the valve and its guide Check the concentricity of the valve head by placing a dial gauge at right angles to the valve head and rotating it on the V shaped support Characteristic Limit allowed 0 03 mm Check the deviation of the valve stem by resting it on a V shaped support and measuring the ex tent of the deformation using a dial gauge Characteristic Limit value allowed 0 1 mm CHAR 26 SCARABEO 50 4T 4V Characteristics Measure the valve guides VALVE GUIDE DIAMETER Specification Desc Quantity Valve guide Standard diameter 4 0 012 mm Valve guide Maximum diameter allowed 4 0 022 mm After measuring the valve guide diameter and the E valve stem diameter check the clearance be tween guide and stem INTAKE Specification Desc Quantity Standard clearance 0 015 0 042 mm Limit allowed 0 06 mm
73. ing side NOTE FIT THE BALL BEARING WITH THE SHIELDING FACING THE OIL SEAL Specific tooling 020151Y Air heater 020376Y Adapter handle 020439Y 17 mm guide 020358Y 37 x 40 mm adaptor Refitting the wheel axle bearing Heat the transmissionside crankcase half using jl c NN a heat gun After lubricating its outer plate insert the bearing using the special adapter and with the aid of a mallet Refit the Seeger ring and the oil seal using the 42 x 47 mm adapter and the handle Specific tooling 020151Y Air heater 020376Y Adapter handle 020363Y 20 mm guide 020359Y 42 x 47 mm adaptor ENG 97 Engine SCARABEO 50 4T 4V Refitting the ub cover Refit the whole wheel axle Refit the intermediate gear paying attention to both shim washers Apply LOCTITE 510 for surfaces to the hub cover and refit it together with the driven pulley shaft Remove the 5 screws and tighten them to the pil 2 prescribed torque MY rt Yomi a BEFORE APPLYING NEW SEALANT WIPE OFF ANY RE MAINING OLD SEALANT FROM THE FAYING SURFACES OF THE HUB COVER AND THE HALF CRANKCASE Locking torques N m Locking torque 11 13 Nm Flywheel cover Cooling hood Remove the manifold and the carburettor by un doing the 2 fixing screws on the head Remove the fastening clamp of the secondary air pipe and disconnect the pipe Remove the 4 front coupling screws 1 of them is a knob and the side fixing scr
74. ket on the cylinder base To avoid damaging the piston keep it firm while removing the cylinder Remove the 2 retainer rings the pin and piston Remove the 3 piston rings NOTE BE CAREFUL NOT TO DAMAGE THE PISTON RINGS WHEN REMOVING THEM Inspecting the small end Measure the inside diameter of the connecting rod small end using a specific micrometer NOTE IF THE CONNECTING ROD SMALL END DIAMETER EX CEEDS THE MAXIMUM DIAMETER ALLOWED SHOWS SIGNS OF WEAR OR OVERHEATING REPLACE THE CRANKSHAFT AS DESCRIBED IN THE CRANKCASE AND CRANKSHAFT CHAPTER Characteristic Max diameter allowed checking the connect ing rod small end 13 030 mm Standard diameter checking the connecting rod small end 1340 025 0 015 mm ENG 107 Engine SCARABEO 50 4T 4V Inspecting the wrist pin Check the pin outside diameter Characteristic Standard diameter pin 13 0 0 004 mm Minimum diameter allowed pin 12 990 mm Inspecting the piston Measure the diameter of the bearings on the pis ton Characteristic Pin seat diameter 13 0 005 0 010 mm Carefully clean the sealing rings housings Measure the sealing rings pistons coupling clearance using suitable sensors as shown in the diagram If clearances measured exceed the limits speci fied in the table below the piston should be re placed by a new one NOTE MEASURE CLEARANCE BY INSERTING THE BLADE OF THE FEELER GAUGE
75. letely Refit the luggage rack Tighten the six screws 6 completely Rear mudguard Remove the tail fairing Disconnect the cable harness of the li cense plate light Unscrew the 4 screws 1 Remove the mudguard 2 CHAS 170 SCARABEO 50 4T 4V Fuel tank Removing the fuel tank Empty the fuel tank Remove the pipe 1 Undo the two screws 2 Disconnect the fuel level probe con nector 3 Remove the tank by lifting it from the front and sliding it off towards the front of the vehicle Front mudguard Remove the complete fork Remove the two screws 12 With the aid of an Allen wrench pre vent the screw 13 from rotating e Remove the nut 14 NOTE WHILE REFITTING PLACE THE NUT 13 CORRECTLY Remove the front mudguard 15 Chassis CHAS 171 Chassis SCARABEO 50 4T 4V Rear central cover e Park the vehicle on its centre stand e Loosen and remove screw 4 and the relevant bushing from both sides e Remove the rear central cover 5 Front central cover e Park the vehicle on its centre stand Unscrew and remove the only screw 1 CAUTION PROCEED CAREFULLY DO NOT DAMAGE THE TABS AND OR THEIR SEATS Remove the front cover 2 by pulling it towards the scooter front part Flyscreen e Remove the 2 screws indicated with spacers and rubber rings CHAS 172 SCARABEO
76. llowed 2 0 20 mm Check the rotor axial clearance using a trued bar as reference plane as shown in the figure NOTE MAKE SURE THE TRUED BAR IS POSITIONED PROPERLY ON THE TWO POINTS ON THE PUMP BODY Characteristic Limit clearance allowed 3 0 09 mm Refitting Check there are no signs of wear on the oil pump shaft or body Check there are no signs of wear or scoring on the oil pump cover If non conforming values or signs of wear are found replace the faulty parts or the assembly Fit the cover on the pump being careful to align the holes 2 on the cover and 2 on the pump body fixing the oil pump on the crankcase Fit the oil pump on the crankcase by tightening the two screws to the prescribed torque ENG 128 SCARABEO 50 4T 4V Engine Fit the pulley on the pump the central screw to the specified torque and the belleville washer Check that there is no seizing and or friction dur ing pulley movement NOTE FIT THE BELLEVILLE WASHER SO THAT ITS OUTER CURVED RIM TOUCHES THE PULLEY Locking torques N m Central screw 12 14 Nm Cover screws 0 7 0 9 Nm Oil pump screws 5 6 Removing the oil sump Remove the oil filler plug transmission cover driving pulley unit with belt and pinion Unscrew the oil drainage cap A shown in the figure and drain out all the oil from the sump Remove the 6 screws shown in the figure Refitting the oil sump Clean and grease
77. main 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 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 uN KEEP OUT OF THE REACH OF CHILDREN TRANSMISSION OIL AND USED FORK OIL CHAR 7 Characteristics SCARABEO 50 4T 4V 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 TYRES CAUTION CHANGING REPAIR MAINTENANCE AND BALANCING ARE IMPORTANT OPERATIONS THAT ARE CARRIED OUT BY QUALIFIED PERSONNEL USING SUITABLE TOOLS THE NEW TYRES MAY BE COVERED WITH A THIN LAYER OF PROTECTIVE COA
78. ment panel light warning light connector 1 Disconnect the speedometer odome ter cable 2 Loosen and remove the three screws 3 e Remove the rear handlebar cover Instrument panel e Remove the front handlebar cover e Loosen and remove the four screws 2 Remove the instrument panel partially CHAS 164 SCARABEO 50 4T 4V SCARABEO 50 4T 4V Chassis Disconnect the speedometer odome ter cable 4 from the instrument pan el Disconnect the main connector 5 Remove the instrument panel Removing the instrument panel glass Remove the instrument panel Push the four tabs 6 and remove the glass 7 Front handlebar cover Removal i CAUTION Park the vehicle on its centre stand Remove the windshield Remove the six screws 1 Release the both upper coupling tongues by pressing slightly the rear handlebar cover Remove the front handlebar cover DO NOT FORCE THE HANDLEBAR COVER EXCESSIVELY TO AVOID BREAKING IT Disconnect the front headlamp light E NOTE connectors 2 and the two turn indi cator connectors 3 WHEN REFITTING MAKE SURE THE TABS ARE COR RECTLY INSERTED CHAS 165 Chassis SCARABEO 50 4T 4V Headlight assy REMOVING THE TURN INDICATORS e Remove the front handlebar cover Release clamp 1 and disconnect the connectors 2 e Unscrew the nuts 3 Removing the headlamp e Remo
79. meter case grease Lithium soap grease NLGI 3 ISO L XBCHAS DIN K3K 20 Fit the pinion in its seating by pushing the start up lever Fit the inlet throat and tighten the 3 screws Make sure the oil sump presents alignment dow els and sealing gaskets Replace the cover by tightening the 12 screws to the prescribed torque Refit the oil filling cap Locking torques N m Transmission cover screws 11 13 Nm End gear ENG 94 SCARABEO 50 4T 4V Engine Removing the hub cover e Remove the transmission cover e Remove the clutch assembly Drain the rear hub oil e Remove the 5 screws indicated in the TOME See also Removing the wheel axle Remove the intermediate gear and the wheel axle together with the gear Upon removing the intermediate gear pay atten tion to the respective shim washers Removing the wheel axle bearings Remove the oil seal and the Seeger ring Using the appropriate punch remove the bearing by pushing from the outside towards the inside of the gear compartment Specific tooling 020363Y 20 mm guide 020376Y Adapter handle 020358Y 37 x 40 mm adaptor ENG 95 Engine SCARABEO 50 4T 4V Removing the driven pulley shaft bearing Remove the Seeger ring inside the cover Remove the oil seal from the outer side Remove the two alignment dowels and position the cover on a surface Position the specific tool on the bearing internal track and remo
80. ng Remove the three screws fastening the headlight assembly to the tail fairing Remove the rear light unit e Hemove the two screws located be hind the headlight Slide off the daylight running stop LED lights Remove the turn indicators by acting on the nuts indicated CHAS 168 SCARABEO 50 4T 4V Chassis Footrest Removal Remove the rear central cover e Loosen and remove the four screws 3 Loosen screw 4 from both sides of the lower cover Slightly lift the footrest rear part and take it out from the internal shield base CAUTION WHEN REFITTING FIRST FIT THE CENTRAL AND THEN THE SIDE TABS Air filter Filter box removal e Park the vehicle on its centre stand e Undo and remove the three screws 1 CHAS 169 Chassis SCARABEO 50 4T 4V Remove the clamp 2 and slide off the fuel pipe Loosen the clamp 3 and slide off the sleeve from the filter box e Remove the entire air filter box Tail guard Remove the luggage rack Remove the rear central cover Undo and remove the six screws 6 Lift the tail fairing Release the cable harnesses of rear light unit While refitting Place the tail fairing on its seat M Connect the cable harnesses of rear light unit NOTE TIGHTEN THE SIX SCREWS 6 COMPLETELY AFTER REFITTING THE LUGGAGE RACK Insert the six screws 6 without tightening them comp
81. ng crankshaft alignment CHAR 22 SCARABEO 50 4T 4V Characteristics Install the crankshaft on the support and measure the misalignment at the 4 points indicated in figure NOTE IF VALUES OTHER THAN THOSE ALLOWED ARE DETEC TED TRY STRAIGHTENING THE CRANKSHAFT BY IN SERTING A WOODEN WEDGE BETWEEN THE HALF SHAFTS OR BY CLOSING THEM WITH A VICE AS NEE DED IF EVEN AFTER THIS OPERATION THE VALUES ARE NOT THOSE ADMITTED REPLACE THE CRANKSHAFT Characteristic Maximum off line allowed A 0 15 mm Maximum off line allowed B 0 02 mm Maximum off line allowed C 0 02 mm Maximum off line allowed D 0 10 mm Measure the inside diameter of the connecting rod small end using a bore meter NOTE IF THE CONNECTING ROD SMALL END DIAMETER EX CEEDS THE STANDARD DIAMETER SHOWS SIGNS OF WEAR OR OVERHEATING REPLACE THE CRANKSHAFT AS DESCRIBED IN THE CRANKCASE AND CRANK SHAFT CHAPTER Characteristic Connecting rod small end diameter 13 0 015 0 025 mm Max diameter allowed checking the connect ing rod small end 13 030 mm Calculate the coupling clearance between the pin and the connecting rod small end Characteristic Pin connecting rod clearance 0 015 0 029 mm Cylinder head Clean all the coupling surfaces thoroughly before servicing the head Pay attention to the position of the springs and valves so as not to change the original position upon refitting them CHAR 23 Characteri
82. ng extractor ENG 122 SCARABEO 50 4T 4V Engine Refitting the crankshaft bearings Support the crankcase firmly on a surface and place it with the crankshaft axle in vertical position Warm the crankcase at 120 C with a thermal gun and support Fit the punch with guide and adapior place the bearing on the punch using grease to keep it from falling Fit the bearing on the crankcase use a mallet but do so with extreme care so as not to damage the engine crankcase limit stop Specific tooling 020359Y 42 x 47 mm adaptor 020364Y 25 mm Guide 020376Y Adapter handle 020360Y 52 x 55 mm adaptor Warm a new main bearing in an oil bath at 120 Place the crankshaft on the support base and fit the bearing with the aid of an adequate pipe sec tion if necessary NOTE USE A NEW BEARING WHEN REFITTING WARNING THE CENTRIFUGAL OIL FILTER IS ON THE FLYWHEEL SIDE HALF SHAFT CONSEQUENTLY DO NOT WASH WITH SOLVENTS OR BLOW COMPRESSED AIR SO THAT NO IMPURITIES LEAK OUT Specific tooling 020265Y Bearing fitting base 008119Y009 Pipe for fitting the shafts and the axles ENG 123 Engine SCARABEO 50 4T 4V Inspecting the crankshaft alignment Install the crankshaft on the support and measure the misalignment at the 4 points indicated in figure NOTE IF VALUES OTHER THAN THOSE ALLOWED ARE DETEC TED TRY STRAIGHTENING THE CRANKSHAFT BY IN SERTING A WOODEN WEDGE BETWEEN THE HALF SHAFTS OR BY
83. ng screws indica ted in the figure ENG 84 SCARABEO 50 4T 4V Engine Removing the driven pulley shaft bearing Slightly heat the crankshaft from the inside to avoid damaging the coated surface With the help of the driven pulley shaft or a pin of the same di ameter to remove the bearing NOTE IN CASE OF DIFFICULTY USE A GENERAL EXTRACTOR FOR 8 MM INSIDE DIAMETERS Refitting the driven pulley shaft bearing Refit the bearing with the aid of a bushing with the same diameter as the bearing external plate after slightly heating the crankcase from the inside NOTE ALWAYS REPLACE THE BEARING WITH A NEW ONE AT EVERY REFIT CAUTION WHEN REMOVING REFITTING THE BEARING TAKE CARE NOT TO DAMAGE THE COVER PAINTED SURFACE Removing the driven pulley Lock the clutch bell with the specific tool Remove the nut the clutch bell and the whole driven pulley assembly NOTE THE ASSEMBLY CAN ALSO BE REMOVED EVEN IF THE DRIVING PULLEY IS MOUNTED Specific tooling AP8140715 Half rings ENG 85 Engine SCARABEO 50 4T 4V Inspecting the clutch drum Make sure that the clutch bell is not worn or dam aged Measure the clutch bell inside diameter Characteristic Clutch bell diameter standard value 107 0 2 0 mm Clutch bell diameter max value allowed after use 107 5 mm Eccentricity measured max 0 20 mm Inspecting the clutch Check the thickness of the clutch mass friction m
84. nk completely Remove the petrol delivery pipe and the vacuum pipe Loosen the clamp and remove the cock Clean the tank and the cock filter with a specific solvent Refit the cock making sure there is an O Ring Turn the cock to the direction it had before it was removed and block the clamp NOTE ENG 130 SCARABEO 50 4T 4V Engine THE FILTER CAN BE UNSCREWED FROM THE COCK TO MAKE FACILITATE CLEANING Removing the carburettor To remove the carburettor from the engine re move the two clamps anchoring the carburettor to the inlet manifold and the air intake sleeves to the filter Remove the petrol supply pipe Disconnect the starter connection Remove the throttle grip cable with the sheath that connects the plate and the support Slide off the carburettor Remove the protection bracket and the starter loosening the screw shown in the figure CAUTION THE CARBURETTOR HAS AN ANTI VIBRATION RUBBER BUFFER FITTED ON THE LOWER SUPPLEMENT OF THE ACCELERATING PUMP BODY UPON REFITTING THE CARBURETTOR ON THE ENGINE MAKE SURE THIS BUF FER IS PRESENT TO AVOID CHECKING IF THE PETROL IN THE FLOAT CHAMBER IS EMULSIFIED Remove the 2 fixing screws shown in the figure the vacuum chamber cover and the spring Remove the vacuum valve and the diaphragm the pin the spring and the corresponding plastic guide WARNING WHILE REMOVING THE COVER PAY ATTENTION NOT TO RELEASE THE SPRING
85. no value is obtained even with this test replace the regulator because it is obviously failing NOTE TO MEASURE THE ABOVE VOLTAGE USE AN ANA LOGUE TESTER THAT CAN MEASURE ALTERNATING VOLTAGES AND KEEP THE ENGINE AT IDLE TO HAVE AN ALTERNATING VOLTAGE WITH A FREQUENCY AS CLOSE AS POSSIBLE TO 50HZ SO AS TO DETECT THE 25 35V a 1900 2000 giri min EFFICIENT VOLTAGE VALUE SUPPLIED BY THE REGU LATOR ABOUT 12V ELE SYS 70 SCARABEO 50 4T 4V Electrical system Recharge system voltage check 3 BATTERY NOT RECHARGING A failure in the direct current section of the voltage regulator may cause the following problems de pending on the type of failure a Protection fuse blows due to overvoltage regulator in short circuit and consequently the battery fails to recharge b Battery fails to recharge regulator interrup ted Maintenance operations a Protection fuse blows regulator in short circuit Check that the cable harness going from the pro tection fuse to the key switch is not damaged which may cause a short circuit to ground thus preventing damaging the regulator 2000 G min 13V 1 5 2A Afterwards measure the resistance between con gt 4000 87 min 34 T 34 5V gt 4A tact 3 Green Orange and contact 2 Black of the voltage regulator with connector disconnected If the value measured is far from that indicated replace the regulator because it is in short circuit b Battery fails
86. ocedure below The procedure is different from that indicated in the vehicle manuals Head tightening nuts only for stud bolt replacement 6 7 N m 135 90 The 45 rotation reduction of the wrench is necessary to avoid stud bolt stretching Inspecting the cylinder head Using a trued bar check that the head surface is i g r1 not worn or distorted i a Check that the camshaft and the rocking lever pin bearings are not worn Check that the head cover surface the intake manifold and exhaust manifold are not worn In case of fault replace the big end Characteristic Maximum run out allowed 0 1 mm Measure the camshaft seat bearings and rocking lever support pins with a bore meter ENG 112 SCARABEO 50 4T 4V Engine CHECKING THE HEAD Specification Desc Quantity Standard diameter mm A 32 015 32 025 Standard diameter mm B 16 0 16 018 Standard diameter mm C 11 0 11 018 Inspecting the timing system components Check that the guide slider and the tensioner pad E are not excessively worn Check that the chain unit the camshaft control pulley and the pinion are not worn If signs of wear are found replace the parts if wear has been found on the chain pinion or pulley replace the entire unit Remove the central screw and the tensioner spring Check that the one way mechanism is not worn Check the condition of the tensioner spring If signs of wear are f
87. odels shown in this publication are available in all Countries The availability of individual versions models should be confirmed with the official aprilia sales network Copyright 2009 aprilia All rights reserved Reproduction of this publication in whole or in part is prohibited aprilia After sales service Aprilia trademark is property of Piaggio amp C S p A SERVICE STATION MANUAL SCARABEO 50 4T 4V This manual provides the main information to carry out regular maintenance operations on your vehicle This manual is intended to aprilia Dealers and their qualified mechanics several concepts have been deliberately omitted as they are considered unnecessary As it is not possible to include complete mechanical notions in this manual users should have basic mechanical knowledge or minimum knowledge about the procedures involved when repairing scooters Without this knowledge repairing or checking the vehicle may be inefficient or even dangerous As the vehicle repair and check procedures are not described in detail be extremely cautious so as not to damage components or injure individuals In order to optimise customer satisfaction when using our vehicles aprilia s p a commits itself to continually improve its products and the relative documentation The main technical modifications and changes in repair procedures are communicated to all aprilia Sales Outlets and its International Subsidiaries These changes will be introduced in the s
88. ool Remove the central nut plus the washer remove the drive and the plastic fan Remove the fixed half pulley Remove the belt the limiting washer and slide off the movable half pulley with its bushing being careful that the rollers and supporting plate fitted loosely on it do not come off Specific tooling 020451Y starting sprocket lock Inspecting the rollers case 1 Check that the bushing and the sliding rings of the movable pulley do not show signs of scoring or deformation 2 Check the roller running tracks on the contact pulley there must be no signs of wear check the state of the faying surface of the belt on the half pulleys movable and fixed 3 Check that the rollers do not show signs of marked facets on the sliding surface and that the metal insert does not come protrude from the plas tic shell borders 4 Check the integrity of the sliding blocks of the contact plate Check that the internal bushing shown in the fig ure does not show signs of abnormal wear and measure the inside diameter A Measure the outside diameter B of the pulley sliding bushing shown in the figure CAUTION DO NOT LUBRICATE OR CLEAN THE BUSHING Characteristic Driving pulley Max diameter ENG 92 SCARABEO 50 4T 4V Engine 20 12 mm Driving pulley Standard diameter 20 021 mm Driving pulley bushing Minimum diameter 19 95 mm Driving pulley bushing Standard diameter 20 0 020
89. orking The regulator is earthed through the electrical system so the regulator body does not earth the circuits inside the regulator There must be insulation between each regulator terminal and the regulator body use the tester to check electric resistance ELE SYS 69 Electrical system SCARABEO 50 4T 4V 2 LIGHTS AND STARTER NOT WORKING Gain access to the voltage regulator by removing the plastic cover on the legshield start the engine and keep running it at idle speed Connect the tester positive probe to terminal No 1 Green and the negative probe to terminal No 2 Black check if there is voltage If there is voltage check that the light remote con trol and its excitation line coming from the elec tronic starter Purple Black PIN 7 Brown PIN 3 work properly Check the cable harness from the light switch to the remote control and whether the switch works properly If no voltage is detected try connecting the nega 12V a 1900 2000 giri min tive probe directly to ground if voltage is detected with this operation check the ground wiring of the regulator otherwise replace the regulator be cause it is failing As a last check measure the voltage supplied by the stator Disconnect the regulator connector and place a tester to detect alternating voltage between the Yellow Black cable 4 and the ground connection see figure Voltage supplied at 2000 rpm must be about 25 35V If
90. ound replace the whole as sembly Inspecting the valve sealings Remove any carbon deposits from the valve pi seats Check the width of the mark on the valve seat Characteristic V with Prussian blue S 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 cutter and then grind Replace the head in case of excessive wear or damage ENG 113 Engine SCARABEO 50 4T 4V Fit the valves into the cylinder head Alternatively test the intake and exhaust valves The test should be carried out by filling the mani fold with fuel and checking that the head does not ooze through the valves when they are just press ed by the fingers Inspecting the valves STANDARD LENGTH OF VALVE Specification Desc Quantity Intake standard length 74 9 mm Exhaust standard length 74 35 mm L Y Measure the diameter of the valve stem at the three positions indicated in the diagram T STANDARD DIAMETER Specification Desc Quantity Intake 3 970 3 985 mm Exhaust 3 960 3 975 mm MINIMUM DIAMETER ADMITTED Specification Desc Quantity Intake 3 958 mm Exhaust 3 945 mm ENG 114 SCARABEO 50 4T 4V Engine Calculate the clearance between the valve and its guide Check the concentricity of the valve head by placing a dial gauge at right angles to the v
91. plate fitting Locks checking Tyre pressure check Installation of mirrors and any possible accessories NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES AS TYRES MAY BURST CAUTION A CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE PRE DE 177 A Air filter 43 169 Battery 74 75 Brake 157 160 Carburettor 39 131 134 Chain 119 Clutch 86 90 E Engine oil 44 F Fork 145 Fuel 47 130 171 Fuses 73 H Headlight 57 166 Hub oil 42 Identification 77 Instrument panel 164 Maintenance 9 39 Mirrors 164 S Saddle Shock absorbers 152 Spark plug 47 67 Stand T Tank 171 Transmission 12 84 94 Tyres 13
92. port Pipe for fitting the shafts and the axles Punch to remove steering bearings from headstock TOOL 31 Tooling Stores code 020055Y 020074Y 020150Y 020151Y 020162Y 020171Y 020265Y TOOL 32 SCARABEO 50 4T 4V Description Wrench for steering tube ring nut Tool to align crankshaft Air heater support Air heater Flywheel extractor Punch for driven pulley roller bearing Bearing fitting base SCARABEO 50 4T 4V Stores code 020288Y 020291Y 020306Y 020329Y 020330Y 020331Y Tooling Description Fork for fitting the piston on the cylinder Tool to fit remove valves Punch for fitting the valve seal rings Vacuum pump Mity Vac Stroboscopic light for timing checking Digital multimeter TOOL 33 Tooling SCARABEO 50 4T 4V Stores code Description 020332Y Digital rpm indicator 020334Y Multiple battery charger D er i E MED 020335Y Dial gauge magnetic support 020340Y Punch to fit flywheel and transmission oil seals 020358Y 37 x 40 mm adaptor 020359Y 42 x 47 mm adaptor TOOL 34 SCARABEO 50 4T 4V Tooling Stores code Description 020360Y 52 x 55 mm adaptor 020362Y 12 mm guide 020363Y 20 mm guide 020364Y 25 mm Guide 020376Y Adapter handle 020431Y Valve oil seal extractor TOOL 35 Tooling Stores code 020432Y 020439Y 020444Y 020448Y 020449Y 020450Y 020451Y 020452Y TOOL 36
93. r brake cable grommet to engine M6x35 1 9 Nm 6 64 Ibf ft Screw fixing rear brake cable clamp to engine M6x35 1 9 Nm 6 64 Ibf ft FRONT BODYWORK UNIT Name Torque in Nm Legshield fixing screw M5x12 2 3 Nm 2 21 Ibf ft Internal shield self tapping retainer 3 9 x14 6 1 Nm 0 74 Ibf ft Clip on badge self tapping retainer 4 2x25 1 1 Nm 0 74 Ibf ft ocrew fixing front mudguard to fork M5x12 2 5 Nm 3 69 Ibf ft TCC screw fixing spoiler to handlebar M8x75 2 1 2 Nm 0 88 Ibf ft CENTRAL BODYWORK UNIT Name Torque in Nm Screw fixing under footrest to chassis M5x9 2 3 Nm 2 21 Ibf ft Screw fixing under footrest to legshield M5x12 2 3 Nm 2 21 Ibf ft Internal shield fixing screw M5x12 1 3 Nm 2 21 Ibf ft Footrest self tapping retainer 5 5x20 4 3 Nm 2 21 Ibf ft Footrest self tapping retainer 5 5x20 2 1 Nm 0 74 Ibf ft Inspection cover fixing screw M6x20 2 3 Nm 2 21 Ibf ft CHAR 15 Characteristics Name Glove box net TBEI fixing screw 2 9x12 6 REAR BODYWORK UNIT Name Tail light fixing retainer to tail fairing 5 5x20 3 Luggage carrier fixing screw M6x45 3 Tail fairing self tapping retainer 3 9x14 6 Nut fixing retroreflector to rear mudguard M4 6 SADDLE UNIT Name Nut fixing helmet compartment to chassis M6 2 helmet compartment hook self tapping retainer 4 2x25 2 Saddle hinge self tapping retainer 3 9 x14 4 Hinge cover fixing nut M5 2 SCARABEO 5
94. rance 0 04 0 16 mm oil Scraper maximum clearance al lowed after use 0 17 mm CHAR 18 SCARABEO 50 4T 4V Characteristics Using a bore meter measure the cylinder inside diameter at three different points according to the directions shown in the figure Check that the coupling surface with the head is not worn or distorted Pistons and cylinders are classified according to their diameter This coupling is carried out in pairs A A B B C C D D Characteristic Maximum run out allowed 0 05 mm Piston rings Alternately fit the 3 sealing rings in the cylinder in the area where it keeps its original diameter Using the piston fit the rings perpendicularly to the cyl inder axis Measure the opening of the sealing rings using a feeler gauge as shown in the figure Replace the piston rings if values higher than those prescribed are measured NOTE BEFORE REPLACING ONLY THE PISTON RINGS MAKE SURE THAT COUPLING CLEARANCE BETWEEN THE SEAL RINGS AND ITS GROOVES AND THAT BETWEEN THE PISTON AND THE CYLINDER ARE AS SPECIFIED IN ANY CASE NEW PISTON SEALING RINGS USED IN COM BINATION WITH A USED CYLINDER MAY HAVE DIFFER ENT BEDDING CONDITIONS THAN THE STANDARD ONES CHAR 19 Characteristics SCARABEO 50 4T 4V SEALING RINGS Name Description Dimensions Initials Quantity 1st Compression ring 39 x 1 A 0 08 0 20 2nd Compression ring 39 x 1 A 0 05 0 20 Oil scraper ring 39 x2 A 0 20 0 70 1s
95. rest supporting bracket to chassis M8 4 Horn fixing screw M6x16 1 Self tapping screw fixing splash guard to chassis 3 9x14 2 Nut fixing fuel tank supporting rubber pads M6 2 STAND UNIT Name Nut fixing stand to engine M10x130 1 SCARABEO 50 4T 4V Torque in Nm 42 Nm 30 98 Ibf ft 36 Nm 26 55 Ibf ft Torque in Nm 36 Nm 26 55 Ibf ft 25 Nm 18 44 Ibf ft 7 Nm 5 16 lof ft 1 Nm 0 74 Ibf ft 10 Nm 7 38 Ibf ft Torque in Nm 35 Nm 25 81 Ibf ft FRONT SUSPENSION UNIT Name Nut fixing pumping member to fork sleeve M10 1 Retainer screw tightening wheel pin fork clamp M6 1 Nut fixing steering series nut M25 1 Nut fixing steering series lock nut M25 1 Torque in Nm 7 Nm 5 16 Ibf ft 12 Nm 8 85 Ibf ft 10 Nm 7 38 Ibf ft 110 Nm 81 13 Ibf ft HANDLEBAR AND CONTROLS UNIT Name Nut fixing mirror to handlebar M8 1 Screw fixing front brake pump clamp M6 2 Nut fixing handlebar screw M10 1 ENGINE UNIT Name Ignition spark plug Driven pulley shaft nut Head cylinder passing nuts Rocking lever adjusting nuts Crankshaft pulley nut Clutch assembly nut Nut fixing filter box to engine M6 1 Flywheel nut Clamp fixing sleeve to carburettor Diam 25 1 Gas curve retainer to carburettor 1 Engine oil drainage plug Engine oil pre filter cap ocrew fixing filter box to engine M6x20 1 Screw fixing starting lever M6x25 1 ocrew fixing engine shock absorber M10x25
96. rettor body accu rately with a degreasing solvent and compressed air Pay special attention to the fuel supply pipe and the pin seat For the minimum circuit make sure the following points are properly cleaned air gauging flow screw controlled outlet section progression holes near the throttle valve For the starter circuit blow the connection pipe properly with the jet This is necessary because the jet support hides other inaccessible internal calibrations Blow the intake jet properly Its outlet section is extremely small and is oriented towards the throttle valve Check that the carburettor body has the closing ball for the minimum circuit pipe Check that the coupling surfaces with the float chamber and the diaphragm are not dented Check that the pipe containing the vacuum is not scratched Check that the throttle valve and the shaft do not show abnormal wear Check that the pin seat does not show abnormal wear Replace the carburettor in case of irregularities NOTE TO AVOID DAMAGES DO NOT INTRODUCE METAL OBJECTS IN THE ADJUSTED SECTIONS ENG 134 SCARABEO 50 4T 4V Engine Wash and blow the minimum jet properly and refit it Accurately wash and blow the components of the maximum circuit the sprayer the diffuser and the jet Introduce the sprayer in the carburettor body with the cylindric part with the biggest diameter towards the diffuser Fit the diffuser
97. s down and cools as well NOTE FAILURE TO FOLLOW THESE OPERATIONS MAY RE SULT IN AN INCORRECT READING OF THE ENGINE OIL LEVEL MAIN 45 Maintenance SCARABEO 50 4T 4V 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 into its tube Remove the cap dipstick 1 again and read the level the oil reaches on the dipstick MAX maximum level MIN minimum level The level is correct when it is close to the MAX level marked on the meas uring dipstick CAUTION EN IN ORDER TO AVOID DAMAGING THE ENGINE OIL LEVEL MUST NEVER EXCEED THE MAX MARK OR FALL BE LOW THE MIN MARK Top up if required TOP UP Do not exceed the MAX mark level when topping up engine oil Pour a small quantity of oil through the tube and wait about one minute so that the oil flows evenly into the crankcase Check the oil level and top up if required Top up with small quantities of oil until the recommended level is reached At the end of the operation screw and 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 IRRETRIEVABLE DAMAGE MAIN 46 SCARABEO 50 4T 4V Maintenance Fuel filter Cleaning the fuel filter Empty the fuel tank
98. steering it is necessary to e Park the vehicle on its centre stand Place the support under the scooter with a soft cloth between them so that the front wheel can move freely and the scooter does not fall CAUTION LN MAKE SURE THE SCOOTER IS STABLE AND FIRM NOTE WHEN CARRYING OUT THIS OPERATION PAY ATTEN TION NOT TO MISTAKE THE CENTRE STAND CLEAR ANCE WITH THAT OF THE FORK REPEAT THIS TEST SEVERAL TIMES BEFORE DECIDING IF THE FORK HAS TO BE ADJUSTED Hold the lower rods of the fork and pull the fork forwards and backwards with the steering in forward position There should be no clearance neither forwards nor backwards If there is some clearance the fork bearings must be adjusted Adjusting bearing clearance e Remove the inside front shield CAUTION PROCEED WITH CAUTION HANDLE PLASTIC AND PAINTED PARTS CAREFULLY TO AVOID SCRATCHING OR DAMAGING THEM SUSP 147 Suspensions SCARABEO 50 4T 4V Remove the bushing 2 mates e Through the hole 3 lock the screw 4 to prevent its rotation NOTE THERE IS A GROOVE ON THE STEERING AXLE WHERE THE SCREW 4 RESTS THIS KEEPS HANDLEBAR IN CENTRE AND PREVENTS IT FROM COMING OUT DRAW THE SCREW 4 AWAY AS FAR AS POSSIBLE BE FORE LIFTING THE HANDLEBAR TO TAKE IT OUT Locking torques N m Nut tightening power 5 50 Nm 36 17 ftlb Remove the nut 5 Pull the screw 4 as much as possible with respect to the
99. stics SCARABEO 50 4T 4V Using a trued bar check that the head surface is not worn or distorted Check that the camshaft and the rocking lever pin bearings are not worn Check that the head cover surface the intake manifold and exhaust manifold are not worn In case of fault replace the big end Characteristic Maximum run out allowed 0 1 mm Fit the valves into the cylinder head Alternatively test the intake and exhaust valves he test should be carried out by filling the mani fold with fuel and checking that the head does not ooze through the valves when they are just press ed by the fingers Measure the camshaft seat bearings and rocking lever support pins with a bore meter CHECKING THE HEAD Specification Desc Quantity Standard diameter mm A 32 015 32 025 Standard diameter mm B 16 0 16 018 Standard diameter mm C 11 0 11 018 CHAR 24 SCARABEO 50 4T 4V Characteristics Measure the unloaded spring length Standard length 31 3 mm e Limit allowed after use 29 3 Remove any carbon deposits from the valve seats Check the width of the mark on the valve seat Characteristic V with Prussian blue Bo Standard value 1 1 3 mm Limit allowed 30 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 cutter and then grind Replace the head
100. support Remove the tail fairing Remove the battery cover 1 Disconnect and remove the battery Remove the fuse boxes 3 and the relay 4 from the supports Unscrew and remove the four screws 5 Unscrew and remove fuel tank cap 6 Remove the fuel collecting bucket tap pet 7 passing it together with the drainage pipe 8 through the tank cover hole of the saddle support CHAS 162 SCARABEO 50 4T 4V Chassis Thread the cable harnesses together with fuse holding locks through the slot located at the front part of the saddle support Lift the saddle support rear part 9 slide it forwards and remove it Side fairings After removing the internal legshield remove the six clips 10 from both sides NOTE TO REFIT THE BUMPERS USE NEW CLIPS Rear rack Park the vehicle on its centre stand Hemove cover 1 Unscrew and remove the screw 2 Unscrew and remove the two screws 3 Remove the luggage rack CHAS 163 Chassis Driving mirrors Removing the rear view mirrors The following information refers to one rear view mirror but it applies to both e Park the vehicle on its centre stand Lift the rubber protection 1 Lock bolt 3 and unscrew the nut 4 completely e Remove the rear view mirror 2 Rear handlebar cover Remove the front handlebar cover Disconnect the instru
101. t Compression ring 39 2 x 1 A 0 08 0 20 1st Oversize 2nd Compression ring 39 2 x 1 A 0 05 0 20 1st Oversize Oil scraper ring 1st 39 2x2 A 0 20 0 70 Oversize 1st Compression ring 39 4 x 1 A 0 08 0 20 2nd Oversize 2nd Compression ring 39 4 x 1 A 0 05 0 20 2nd Oversize Oil scraper ring 2nd 39 4 x 2 A 0 20 0 70 Oversize 1st Compression ring 39 6 x 1 A 0 08 0 20 3rd Oversize 2nd Compression ring 39 6 x 1 A 0 05 0 20 3rd Oversize Oil scraper ring 3rd 39 6 x 2 A 0 20 0 70 Oversize CHAR 20 SCARABEO 50 4T 4V Characteristics Crankcase crankshaft connecting rod A C 4 i y EE AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CRANKCASE Name Description Dimensions Initials Quantity Half shaft transmission 14 0 0 005 A side Half shaft flywheel side 16 0 0 005 B Connecting rod 14 8 0 05 0 C Spacer tool 45 00 Fitting clearance E D 0 15 0 30 Characteristic Clearance between crankshaft and connecting rod A 0 15 0 30 mm CHAR 21 SCARABEO 50 4T 4V Characteristics Measure the bearings along X and Y axes Characteristic Crankshaft rolling surface transmission side 20 0 012 0 025 mm Crankshaft rolling surface flywheel side 17 0 007 0 mm Check that the crankshaft cone the tab fitting the oil seal flow the knurling and the threaded shanks are in good working order In case of failure replace the crankshaft Specific tooling 020074Y Support base for checki
102. t after cleaning the faying surface carefully Fit the head in the cylinder stud bolts and tighten the 4 fixing nuts to the prescribed torque Specific tooling 020450Y Tool for fitting removing the camshaft Fit the pins intake rocker and exhaust rocker Lubricate the 2 rocking levers through the holes NOTE WHEN REMOVING THE CAMSHAFT BEARING IT IS ES SENTIAL TO REPLACE THE BEARING WITH A NEW ONE Tighten the rocking lever pin clamping screw to the prescribed torque Repositon the Seeger ring retaining the camshaft Locking torques N m Rocking lever axle screw 3 4 ENG 118 SCARABEO 50 4T 4V Engine Finish the head tightening following the proce dure below screw the four head nuts to an initial torque at two crossed sequences Afterwards tighten the nuts with 2 turns of 90 each to be done at two crossed sequences Finish the tightening of the head to the crankcase with the 2 side screws NOTE SHOULD THE CRANKCASE OR THE CYLINDER STUD BOLTS BE REPLACED IT IS NECESSARY TO CARRY OUT AN INITIAL TIGHTENING PLUS OTHER 3 TURNS OF 90 EACH AT 3 CROSSED SEQUENCES Locking torques N m Head cylinder passing nuts 6 7 4135 90 Nm upon first assembly upon refitting tighten again at 6 7 90 90 Nm Head cover screws 8 10 Nm Refitting the timing chain Fit the timing chain sliders in their corresponding places as well as the screw and the spacer as shown in the figure Tight
103. t cylinder 4 Fit circlips 3 Fit the brake calliper cover 1 Check the brake fluid Fill Bleeding the braking system NOTE IF THERE IS AIR IN THE HYDRAULIC SYSTEM THE WATER WILL ABSORB MOST OF THE POWER OF THE BRAKE MAIN CYLINDER AND THEREFORE IT WILL REDUCE THE CALLIPER BRAK SYS 158 SCARABEO 50 4T 4V Braking system PERFORMANCE WHEN BRAKING THE PRESENCE OF AIR IS SIGNALLED BY THE SPONGI NESS OF THE BRAKE CONTROL AND POOR BRAKING EFFICIENCY CAUTION CONSIDERING THE DANGER POSED FOR VEHICLE AND RIDER IT IS STRICTLY NECESSARY TO BLEED THE HYDRAULIC SYSTEM AFTER REFITTING BRAKES AND CARRYING OUT REG ULAR MAINTENANCE OPERATIONS e Remove the protection cap 1 from E 1 Jf the bleeder spout 2 Connect a glass pipe to the bleed plug a 2 CAUTION t E f a 1 ea DO NOT DIRT THE PADS OR THE DISC WITH BRAKE FLU ID Keep the free part of the glass tube in a clean container Pull the brake lever 5 slowly to the end of the stroke two or three times Then keep it completely pulled CAUTION LOOSEN THE BLEED PLUG SPOUT 2 AND CHECK THE RESERVOIR BRAKE FLUID LEVEL 6 DO NOT EMPTY THE RESERVOIR COMPLETELY SINCE THIS MAY FUR THER CAUSE AIR TO ENTER THE BRAKING SYSTEM Loosen the bleed plug spout 2 and check if there are bubbles in the glass tube CAUTION BEFORE RELEASING THE BRAKE LEVER 5 CLOSE THE BLEED PLUG 2 TO PREVENT WATER FROM E
104. the faying surfaces Apply LOCTITE 510 on the sump surface and tighten the 6 fixing screws to the prescribed torque Refit the driving pulley unit belt pinion and trans mission cover WHEN TESTING THE LUBRICATION SYSTEM REFER TO THE CRANKCASE AND CRANKSHAFT CHAPTER RE GARDING LUBRICATION OF THE CRANKSHAFT AND CONNECTING ROD Locking torques N m Oil sump screws 8 10 Nm ENG 129 Engine SCARABEO 50 4T 4V Fuel supply Disconnect the fuel supply and the vacuum suc tion pipe from the carburettor Check that there are no fuel leaks between the two tubes Close the fuel outlet pipe Using a MITIVAC pump apply 0 1 vacuum bar on the cock Make sure that the vacuum is kept stable and that there are no fuel leaks Reconnect the vacuum pipe to the manifold Place the fuel pipe with the outlet at the cock height Turn the engine by using the starter motor for 5 seconds with the carburettor at idle Measure the fuel by means of a graded burette NOTE THE MEASUREMENT MAY BE DISTORTED BY THE IN CORRECT NUMBER OF REVS OR BY THE WRONG POSI TION OF THE TUBE IN THIS CASE THE TENDENCY IS TO OBTAIN A REDUCED FUEL CAPACITY THE VACUUM IN TAKE ON THE MANIFOLD HAS A SECTION INTENTION ALLY REDUCED FOR THE PURPOSE OF ENHANCING VACUUM PULSES ENSURING A REGULAR COCK CA PACITY Specific tooling 020329Y Vacuum pump Mity Vac Characteristic Minimum capacity 20 cc Empty the fuel ta
105. the filtering element made of sponge C Wash the filter with water and neutral soap then dry with a clean cloth and short blasts of com pressed air While cleaning the filter check the condition of the reed valve D and fit it back in place on the housing Before closing the cover of the SAS housing check the good condition of the sealing O ring re place it if damaged or deformed NOTE The reed valve can be inserted in one direction only on the SAS housing P TY ey ATE URS re Cai e A s MAIN 52 INDEX OF TOPICS E ectricat SYSTEM ELE SYS Electrical system SCARABEO 50 4T 4V KEY 1 Multiple connectors Instrument panel License plate lamp installation Instrument panel lighting bulb Front left turn indicator Oe Or uec oU NS High low beam bulb ELE SYS 54 SCARABEO 50 4T 4V 7 Fuel gauge 8 Horn 9 Left light switch 10 Key switch 11 Right light switch 12 Front stop switch 13 Rear stop switch 14 Fuel level sensor 15 Automatic starter 16 Resistor 17 Left rear turn indicator 18 Tail light assembly 19 Rear right turn indicator 20 Voltage regulator 21 Alternator 22 Pick up 23 Start up relay 24 STARTER MOTOR 25 26 Battery 2 Main fuses 28 Auxiliary fuses 29 Light logic relay 30 Carburettor heater 31 Engine temperature sensor 32 Coil 33 Spark plug 34 Secondary air 35 ECU Diagnosis 36 ECU 37 Front right turn indicator CABLE COLOUR
106. the vehicle on its centre stand CAUTION PLACE AN APPROPRIATE SPACER X UNDER THE REAR WHEEL TO PREVENT IT FROM FALLING AND DRAGGING THE AIR FILTER CONTAINER INTO THE CHASSIS Remove the fairing rear part CAUTION HOLD THE REAR PART OF THE FRAME TO PREVENT IF FROM FALLING WHILE REMOVING THE SHOCK ABSORBER Remove the upper screw 1 and the washer Locking torques N m Upper screw tightening power 50 Nm 36 17 ftlb Remove the lower screw 2 and the washer Locking torques N m Lower screw tightening power 25 Nm 18 08 ftlb e Hemove the shock absorber 3 Centre stand e Park the vehicle on its centre stand Place a support under the vehicle so that it does not fall after the centre stand is removed CAUTION LN SUSP 153 Suspensions SCARABEO 50 4T 4V MAKE SURE THE SCOOTER IS STABLE AND FIRM Remove the two springs 1 e Unscrew the nut 2 and slide off the pin To refit carry out the removal operations but in reverse order and tighten the nut to the prescribed torque Locking torques N m Central stand to chassis fixing screw 42 5 SUSP 154 INDEX OF TOPICS Brana SYSTEM BRAK SYS Braking system SCARABEO 50 4T 4V Interventions rules When pads are worn the brake fluid level in the reservoir decreases to automatically compensate pad wear The front brake fluid reservoir 1 is located on the end part to the right of the handlebar next to
107. to recharge regulator interrupted To check if there is any failure in the voltage reg ulator recharge section first connect 2 testers to the battery one to detect voltage and the other to detect current as indicated in the second figure and follow the procedure below Start the engine temporarily connect the red cable to the battery positive terminal in order to avoid damaging the device that measures current Check that there is 13V voltage minimum battery charged and a recharge current of 1 5 2A with the lighting system and the starter disabled To disable the lighting system remove the light re mote control As the engine rpm increases the current and the recharge voltage increase with rpm over 4000 ELE SYS 71 Electrical system SCARABEO 50 4T 4V there must be a recharge current of about 4 5A by enabling both the lighting system the starter the stop light and by supplying power to the horn the current values 2 5A and a voltage value of 14 14 5V regulator threshold voltage can be detec ted If values other than those above are detected replace the regulator otherwise check the ca ble harness and the connections Electric characteristic voltage regulator resistance 8 MO Start up system check To check relay operation Power supply with a voltage of 12 V and two male terminals 85 86 Using a tester in ohmmeter function check the circuit continuity betwe
108. tongues the rear handlebar cover does not allow to remove it completely Lift the handlebar a few centimetres Remove the plastic gasket 6 Loosen the tightening nut 7 using an adequate open wrench CAUTION DO NOT TIGHTEN THE ADJUSTMENT NUT 8 TOO MUCH BECAUSE IT MAY DAMAGE THE STEERING BEARINGS Tighten the adjustment nut 8 but do not eliminate the bearings clearance completely Check clearance as described above Make sure the front fork can move all long its stroke from left to right or vice versa rotating freely and smoothly Keep the adjustment nut 8 into position using an adequate wrench and tighten the tight ening nut 7 Check bearing clearance again after tightening the nut to make sure the adjustment is still correct Removal CAUTION PLACE AN APPROPRIATE SUPPORT UNDER THE SCOOTER TO PREVENT IT FROM FALLING SUSP 148 SCARABEO 50 4T 4V Suspensions CAUTION Park the vehicle on its centre stand Remove the wheel DO NOT FORCE THE CABLES THE TUBES THE WIRES OR THE ELECTRICAL CONNECTORS CAUTION Remove the handlebar completely Hold the handlebar so that it does not put weight on the electrical wires and cables Slide off and remove the rubber gasket 5 Unscrew and remove the tightening nut 6 Unscrew and remove the adjustment nut 7 WHEN REMOVING THE FORK PAY ATTENTION TO COLLECT ALL THE BALLS OF THE FORK BEARINGS THE BALLS ARE
109. tral unit must be done with the engine off If after replacement the vehicle starts properly the control unit is failing and must be replaced If the failure persists check the alternator and the stator components as follows After a sight control of the electrical connections use a specific tester to measure the stator winding and the pick up see table If checks on the loading coil and pick up show fail ures replace the stator and the failing compo nents Disconnect the connector on the flywheel cover and measure the resistance between either con tact and the earth Specific tooling 020331Y Digital multimeter PICK UP CHECK Specification Desc Quantity 1 1 Brown cable and ground 7 1700 STATOR WINDING CHECK Specification Desc Quantity 1 1 Black cable and ground 10 ELE SYS 66 SCARABEO 50 4T 4V Electrical system Marrone Nero Pick Up Statore No spark plug Once the lack of power to the spark plug has been detected and the LED indicates it can be ignited follow this procedure Pick Up Check Disconnect the electronic starter connector and check continuity between terminal No 3 Brown and terminal No 4 Blue The check includes the Pick Up and its power line If a break in the circuit is found check again the flywheel and the engine ground connectors If non conforming values are measured replace the Pick Up otherwise repair the cable harness Electric chara
110. tted with a variable advance elec tronic device There are two timing references on the flywheel cover in order to ensure a better pre cision when detecting the reference on the fan CAUTION IF FLASH INDICATIONS ARE UNSTABLE AND THE RPM INDICATION DOES NOT CORRESPOND WITH REAL EN GINE SPEED VARIATION FOR EXAMPLE VALUES SHOWN ARE HALVED INSTALL A 10 15 KO RESISTIVE CABLE CONNECTED IN SERIES TO AN HV CABLE IF THE IRREGULAR READING CONTINUES AFTER THIS OPERA TION CHECK THE COMPONENTS OF THE IGNITION SYS TEM When the advance check is carried out with a stroboscopic gun add 10 flywheel keying to the table below MAIN 40 SCARABEO 50 4T 4V Maintenance MAPPA ATTIVAZIUNE SAS DUTY CYCLES SAS setup map duty cycle 16 rom values LJ mi Li ELI I ma LI E rors m c iL CL eL i B Spark plug Check the spark plug according to the indications in the maintenance table To reach it e Remove the rear central cover CAUTION BEFORE CARRYING OUT THE FOLLOWING OPERATIONS AND IN ORDER TO AVOID BURNS LEAVE ENGINE AND SILENCER TO COOL OFF TO AMBIENT TEMPERATURE Disconnect the cap Clean off any trace of dirt from the spark plug base by blowing compressed air Unscrew the spark plug and remove it from its seat making sure no dust or dirt gets into the cylinder Check that spark plug electrode and central porcelain ins
111. ttery If even after this operation the turn indicators fail to turn on check that the cable harness is not damaged and the switch works properly if these last two tests have a positive result replace the regulator because it is certainly not functioning properly Specific tooling 020331Y Digital multimeter Fuses CAUTION DO NOT REPAIR FAULTY FUSES NEVER USE FUSES OTHER THAN THE ONES SPECIFIED A SHORT CIRCUIT MAY DAMAGE THE ELECTRICAL SYSTEM OR EVEN CAUSE A FIRE NOTE IF A SPARE FUSE IS USED SUPPLY ANOTHER OF THE SAME TYPE IN THE CORRESPONDING FITTING ELE SYS 73 Electrical system SCARABEO 50 4T 4V To check Set the ignition switch to OFF to avoid an accidental short circuit Remove the battery cover e Extract one fuse at a time and check if filament 2 is broken Before replacing the fuse find and solve if possible the reason that caused the problem Then replace the fuse if damaged with spare fuse lt lt 3 gt gt or with one of the same current rating Refit the battery cover NOTE IF A SPARE FUSE IS USED SUPPLY ANOTHER OF THE SAME TYPE IN THE CORRESPONDING FITTING FUSE DISTRIBUTION 15A Fuse main fuse 10A Fuse control unit 7 5A Fuse all the electric loads except for the light circuit fed with alternating current Checking the fuses is necessary whenever an electrical component fails to operate or is malfunc tioning or when the engine does
112. ty exceeds the limit value Characteristic Maximum eccentricity 0 25 mm ro 4 SUSP 143 Suspensions SCARABEO 50 4T 4V WHEEL RIM Using a dial gauge check that the radial eccen tricity A and the axial eccentricity B of the wheel rim 3 do not exceed the limit value An excessive eccentricity is usually caused by worn or damaged bearings Replace the wheel rim 3 if after the bearings are replaced the value is not within the specified limit Characteristic Maximum radial and axial eccentricity 2mm Check the tyre conditions CAUTION CHECK TYRE TREAD FOR WEAR BADLY WORN TYRES f 1 COMPROMISE TRACTION AND VEHICLE HANDLING a REPLACE TYRES WHEN WORN OR IF THERE IS A PUNC JE 4 TURE BIGGER THAN 5 MM IN THE TREAD SOME TYRE TYPES HOMOLOGATED FOR THIS VEHICLE FEATURE P WEAR INDICATORS CHECK THAT THE INFLATION een A VALVES 1 HAVE THEIR CAPS FITTED IN ORDER TO gt AVOID UNEXPECTED FLAT TYRES P MEI cm BALANCE THE WHEEL AFTER A TYRE IS MENDED Refitting the front wheel CAUTION N WHEN REMOVING OR REFITTING THE WHEEL PAY SPECIAL ATTENTION NOT TO DAMAGE THE BRAKE CABLE THE DISCS AND THE PADS BEFORE CARRYING OUT THE FOLLOWING OPERATIONS COOL DOWN THE ENGINE AND THE SILENCER TO AMBIENT TEMPERATURE TO AVOID POSSIBLE BURNS Apply a thin layer of lubricating grease inside the speedometer transmission in the external seats of the wheel hub and on th
113. ubsequent editions of the manual In case of need or further queries on repair and check procedures consult aprilia CUSTOMER DEPARTMENT which will be prepared to provide any information on the subject and any further communications on updates and technical changes related to the vehicle 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 A 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 CHAR oO o r J Z gt 5 8 D o o TOOL MAINTENANCE MAIN ENG VE ELECTRICAL SYSTEM ELE SYS ENGINE FROM VEHICLE ENG SUSP BRAK SYS BRAKING SYSTEM CHAS I gt T o o PRE DELIVERY PRE DE INDEX OF TOPICS Characteristics CHAR Characteristics SCARABEO 50 4T 4V Rules Safety rules GENERAL PRECAUTIONS AND INFORMATION When repairing dismantling and reass
114. ughly Apply a specific filter oil over all the surface Engine oil Replacement CAUTION PARK THE VEHICLE ON SAFE AND LEVEL GROUND e Park the vehicle on its centre stand CAUTION WAIT SOME MINUTES UNTIL THE ENGINE AND THE EXHAUST SYSTEM ARE COLD s Stop the engine and let it cool off so that the oil in the crankcase flows down and cools as well Unscrew and pull out the measuring cap dipstick 1 Place a collecting container with 850 cm capacity under the engine oil filter MAIN 44 SCARABEO 50 4T 4V Maintenance Unscrew and remove the oil drainage plug 2 and then drain all the engine oil into the collecting container Slide off the mesh filter and clean it Insert the mesh filter Screw and tighten the engine oil drain age plug 2 When refilling add approx 850 cm of engine oil through the fill opening Screw and tighten the measuring cap dipstick 1 Start the engine and let it run for several minutes Stop the engine and let it cool down e Check the engine oil level again using the cap dipstick 1 and top up if necessary without exceeding the MAX level NOTE USE RECOMMENDED OIL ONLY REFER TO THE RECOMMENDED PRODUCTS TABLE Check e Park the vehicle on its centre stand CAUTION WAIT SOME MINUTES UNTIL THE ENGINE AND THE EXHAUST SYSTEM ARE COLD Stop the engine and let it cool off so w that the oil in the crankcase flow
115. ulator do not have carbon deposits or corrosion if necessary remove them Use a feeler gauge to check the electrode gap and if necessary adjust it Make sure the washer is in good conditions Fit the washer and then finger tighten the spark plug Tighten to the specified torque Characteristic Spark plug electrode gap 0 7 0 8 mm Locking torques N m Spark plug 12 14 MAIN 41 Maintenance SCARABEO 50 4T 4V Hub oil Check Ride a few kilometres until the regular working temperature is reached then stop the engine Rest the vehicle on its stand Remove the tap dipstick 2 and clean it with a cloth Reinsert the cap dipstick 2 into its housing and screw it again completely Then pull it out again to check the oil level e The oil level is correct if it reaches the indicated mark RIDING THE VEHICLE WITH INSUFFICIENT LUBRICATION OR CONTAMINATED OR NOT RECOMMENDED LUBRI CANTS ACCELERATES THE WEAR AND TEAR OF MOV ING PARTS AND CAN CAUSE IRRETRIEVABLE DAMAGE Replacement To ensure long lasting and optimal vehicle per formance change oil following the frequency indi cated in the scheduled maintenance tables For change Ride a few kilometres until the regular working temperature is reached then stop the engine Park the vehicle on its centre stand Place a container with 200 cm mini mum capacity under the drainage plug 1 Unscrew t
116. ump shield screw Pick up screws otator screws 4 5 Nm 3 32 If ft 4 5 Nm 3 32 Ibf ft 3 5 Nm 2 58 lof ft 3 5 Nm 2 58 Ibf ft Rocking lever axle and camshaft bearing screw Camshaft pulley screw 3 5 Nm 2 58 lof ft 13 Nm 9 60 Ibf ft Chain tensioner pad screw Screws fixing head and cylinder to crankcase Floating head cover screws 5 5 Nm 4 06 Ibf ft 6 Nm 4 43 lof ft 9 Nm 6 64 Ibf ft 6 5 Nm 4 79 Ibf ft When assembling the new stud bolts nut tightening involves 3 turns of 90 each after the first locking at 6 5 Nm 4 79 Ibf ft consequently 6 5 Nm 4 79 Ibf ft 90 90 90 at crossed passages EXHAUST UNIT Name Screw fixing silencer to engine M8x70 2 Nut fixing silencer flange to cylinder M6 2 Torque in Nm 22 5 Nm 16 59 Ibf ft 10 Nm 7 38 Ibf ft Screw fixing heat shield to silencer M6x20 3 FRONT WHEEL UNIT Name Wheel pin retainer M12 1 Brake disc retainer M6 5 REAR WHEEL UNIT Name Rear wheel fixing nut M16 1 FRONT BRAKE UNIT Name Brake pump clamp retainer M6 2 Nut fixing brake pipe to front mudguard M6 1 7 Nm 5 16 Ibf ft Torque in Nm 35 Nm 25 81 Ibf ft 10 Nm 7 38 Ibf ft Loctite 243 Torque in Nm 112 Nm 82 61 Ibf ft Torque in Nm 10 Nm 7 38 Ibf ft 3 Nm 2 21 Ibf ft Screw fixing front brake calliper to fork M8x35 2 21 Nm 15 49 Ibf ft Loctite 243 REAR BRAKE UNIT Name Torque in Nm Screw fixing rea
117. ve said bearing with the aid of a press Specific tooling 020452Y Pipe to remove and refit the driven pulley shaft Position the specific pipe on the internal track of the bearing and on the pulley shaft toothing side as indicated in the figure and expel the driven pul ley shaft with the aid of a press Specific tooling 020452Y Pipe to remove and refit the driven pulley shaft Inspecting the hub shaft Check the three shafts for wear or distortions on the toothed surfaces on the bearing housings and the oil seal positions In faults are found replace the damaged parts Check capacity A of the transmission gear wear deformations etc Check the pulley shaft seat Superficial wear B may indicate irregularities in the crankcase seats or in the pulley shaft housing Inspecting the hub cover Check that the coupling surface is not dented or distorted If faults are found replace the hub cover ENG 96 SCARABEO 50 4T 4V Engine Refitting the driven pulley shaft bearing Support the inner track of the bearing from the outside of the hub cover with the specific tool posi tioned under the press and insert the driven pulley shaft Refit the oil seal flush with the cover Specific tooling 020452Y Pipe to remove and refit the driven pulley shaft Heat the hub cover and insert the bearing using the specific punch e Fit the circlip with the concave or radial part on the bear
118. ve the front handlebar cover o Unscrew and remove the screw 3 and collect the rear spring NOTE WHEN REFITTING MAKE SURE THE LIGHT BEAM IS COR RECTLY ADJUSTED e Unscrew and remove the 4 screws 5 and remove the headlamp frame Operating with caution remove the two sealing fins and remove the headlamp from the front part CHAS 166 SCARABEO 50 4T 4V Chassis Legshield o Remove the fork Remove the front central cover Remove the control unit Loosen and remove the four screws 8 e Remove the front shield 9 Knee guard e Remove the footrest jS Remove the rubber gasket 3 from eini the ignition switch 7 Loosen and remove screw 4 from both sides M Open the glove box lid 5 Unscrew and remove the screw 6 Remove the front central cover e Unscrew and remove the two screws f Press the sides of the external leg shield up to the arrows A B C and pull it Remove the leg shield back plate 8 CHAS 167 Chassis SCARABEO 50 4T 4V Removing the ignition key switch when on off Remove the front central cover Disconnect the two electric connectors 1 and 2 Loosen and remove the two screws 3 special Remove the whole ignition lock NOTE WHILE REFITTING REPLACE THE SCREW 3 OF SPE CIAL TYPE WITH A NEW ONE Taillight assy Remove the tail fairi
119. w gasket and tighten the 2 screws to the prescribed torque Fit the spring with the central screw and tighten it to the prescribed torque Fit the spark plug Locking torques N m Timing chain tensioner screw 8 10 Nm Timing chain tensioner central screw 5 6 Ignition spark plug 10 15 Nm Refitting the rocker arms cover Carry out the removal operations but in reverse order and tighten the four fixing screws to the pre scribed torque NOTE FIT A NEW O RING ON THE TAPPET COVER ENG 120 SCARABEO 50 4T 4V Engine Refitting the intake manifold Fit the cover sealing gasket on the head Fit the 2 covers Fit the intake manifold and lock the 2 screws to the prescribed torque Fitthe carburettor on the intake manifold and lock the clamp Fit the secondary air pipe and fix it with the ap propriate clamp NOTE FIT THE CARBURETTOR THROUGH THE SUPPLEMENT ON THE MANIFOLD Locking torques N m Intake manifold screw 7 9 Nm Crankcase crankshaft First remove the following units Driving pulley Driven pulley Final reduction greasing Flywheel Oil pump plus stator Cylinder piston head unit Starter motor plus wire unit See also Electric fan Splitting the crankcase halves Remove the 10 crankshaft coupling screws Detach the crankcase keeping the half crankshaft connected to the engine crankcase half on the transmission side Remove the crankshaft CAUTION THE

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