Aprilia Scarabeo 50 Ie 100 4t Digital Workshop Repair Manual 2003-2006
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DESCRIPTION:
This manual contains information covering normal servicing procedures. – The information and illustrations contained in this manual are current as of the manual’s publication. Since aprilia s.p.a. strives to always improve the quality and usefulness of its vehicles, changes may be made to the vehicles at any time. Thus, it is imperative that users of this manual understand that some information may be out of date for some vehicles. Be sure that the information in this manual applies to the vehicle that you are servicing before you begin any service operations.
This publication is intended for aprilia dealers and their trained and qualified mechanics. The description of many service and repair operations is intentionally omitted, as it is assumed that the users of this manual have basic mechanical training, basic knowledge of the procedures regarding motor vehicle repair, and have available to them all current information published by aprilia concerning the vehicle.
Without these things, the repair or servicing of the vehicle could be affected and could lead to a dangerous condition or accident for the servicing mechanic or the operator.
- This manual does not describe all of the procedures necessary to repair and service the vehicle in detail. Therefore, it is important to be particularly careful in order to avoid any damage to the vehicle, its parts, or to cause injury to the mechanic or the rider.
- Changes in the technical specifications and servicing procedures that become necessary as a result of changes to aprilia vehicles will be documented and distributed to all aprilia dealers.
TABLE OF CONTENTS:
FOREWORD 1
INTRODUCTION 1
SAFETY WARNINGS 1
GENERAL SAFETY RULES 2
CARBON MONOXIDE 2
FUEL 2
HOT COMPONENTS 2
USED ENGINE OIL 2
BRAKE FLUID 2
COOLANT 2
BATTERY HYDROGEN GAS AND
ELECTROLYTE 2
PRECAUTION AND GENERAL INFORMATIONS 3
ELECTRICAL CONNECTORS 4
TIGHTENING TORQUES 4
HOW TO USE
YOUR SERVICE AND REPAIR MANUAL 5
TECHNICAL DATA 8
TIGHTENING TORQUES TABLE 10
TIGHTENING TORQUES TABLE 11
TIGHTENING TORQUES TABLE 100 12
LUBRICANT CHART 13
REGULAR SERVICE INTERVAL CHART 14
IDENTIFICATION DATA 17
FRAME NUMBER 17
ENGINE NUMBER 17
ARRANGEMENT OF THE MAIN ELEMENTS 18
ARRANGEMENT OF THE MAIN ELEMENTS 100 18
ARRANGEMENT OF THE INSTRUMENTS /
INSTRUMENTS AND INDICATORS 19
THROTTLE 20
CHECKING THE OPERATION OF THE THROTTLE
CONTROL 20
ADJUSTING THE THROTTLE CONTROL 21
FAIRINGS 22
REMOVING THE LUGGAGE RACK 22
REMOVING THE INSPECTION COVER 22
REMOVING THE REAR PART OF THE FAIRING 22
REMOVING THE REAR MUDGUARD 24
REMOVING THE FOOTBOARD 24
REMOVING THE LOWER SHIELD 24
REMOVING THE FRONT COVER 25
REMOVING THE FRONT INNER SHIELD 25
REMOVING THE REAR-VIEW MIRRORS 26
REMOVING THE FRONT HANDLEBAR COVER 26
REMOVING THE REAR HANDLEBAR COVER 27
REMOVING THE FRONT OUTER SHIELD 27
REMOVING THE BUMPER 28
REMOVING THE FRONT MUDGUARD 28
REMOVING THE SADDLE SUPPORT 29
REMOVING THE SADDLE SUPPORT 100 30
FUEL TANK 31
FUEL 31
DRAINING THE FUEL TANK 32
REMOVING THE FUEL PUMP FLANGE 32
CLEANING THE FUEL FILTER 32
DRAINING THE FUEL TANK 100 33
CLEANING THE FUEL FILTER 33
CHECKING THE FUEL LEVEL GAUGE UNIT 33
REMOVING THE FUEL LEVEL GAUGE UNIT 33
REMOVING FUEL TANK 34
REMOVING FUEL TANK 100 34
MIXER OIL TANK 35
CHECKING 35
DRAINING 35
REMOVAL 36
BLEEDING THE MIXER OIL TANK 36
DISASSEMBLING THE OIL PUMP 37
FUEL PUMP 37
BULBS 38
HEADLIGHT 38
ADJUSTING THE HEADLIGHT BEAM VERTICALLY 38
CHANGING THE HEADLIGHT BULBS 39
REMOVING THE HEADLIGHT 39
FRONT AND REAR DIRECTION
INDICATORS 40
CHANGING THE BULB 40
CHANGING THE FRONT DIRECTION
INDICATOR 100 40
REMOVING THE COMPLETE DIRECTION
INDICATOR 41
REAR LIGHT 42
CHANGING THE REAR LIGHT BULB 42
CHANGING REAR DIRECTION INDICATOR
LAMP BULBS 42
REMOVING THE REAR LIGHT 42
NUMBER PLATE LAMP BULB 100 43
CHANGING NUMBER PLATE LAMP BULB 43
REMOVING NUMBER PLATE LAMP BULB 43
DASHBOARD 43
CHANGING THE DASHBOARD BULBS 43
DASHBOARD 100 44
CHANGING THE DASHBOARD BULBS 44
REMOVING THE COMPLETE DASHBOARD 45
REMOVING THE DASHBOARD
TRANSPARENT SCREEN 45
BRAKES 46
DISC BRAKES 47
FRONT AND REAR BRAKE 48
BRAKE PADS 50
CHECKING WEAR OF THE BRAKE PADS 50
CHANGING THE BRAKE PADS 50
BLEEDING THE BRAKING SYSTEM 51
BRAKE CALIPERS 52
REMOVING THE FRONT BRAKE CALIPER 52
REMOVING THE REAR BRAKE CALIPER 52
REMOVING THE REAR BRAKE SHOES 100 53
TRANSMISSION 54
CHECKING THE TRANSMISSION OIL LEVEL 54
CHANGING THE TRANSMISSION OIL 54
WHEELS / TIRES 55
INSPECTING THE WHEELS 55
TIRES 55
FRONT WHEEL 57
DISASSEMBLY 57
CHECKING 58
CONTENTS
Release 00 2003-02 7
Scarabeo 50 IE-50/100 4T
REASSEMBLY 58
REAR WHEEL 60
DISASSEMBLY 60
CHECKING THE ENGINE FULCRUM AXIS 61
IGNITION SWITCH / STEERING LOCK 61
REMOVAL 61
AIR CLEANER 62
REMOVAL THE AIR FILTER 62
REMOVING THE COMPLETE AIR CLEANER
CASING 62
AIR CLEANER 100 64
REMOVAL THE AIR FILTER 64
CLEANING 64
REMOVING THE COMPLETE AIR CLEANER
CASING 65
FORK HEAD 66
CHECKING THE BEARING PLAY 66
ADJUSTING THE BEARING PLAY 66
REMOVING THE FORK HEAD BEARINGS 67
FRONT FORK 68
REMOVING THE COMPLETE FORK 68
DISASSEMBLING THE LOWER FORK LEGS 68
REMOVING THE COMPLETE DAMPER 68
REAR SUSPENSION 69
REMOVAL 69
EXHAUST SILENCER 69
DISASSEMBLY 69
ENGINE 70
REMOVING THE ENGINE FROM THE FRAME 70
ENGINE MOUNTING BUSHINGS 73
REMOVAL 73
BATTERY 74
CHECKING AND CLEANING THE TERMINALS AND
CLAMPS 75
REMOVING THE BATTERY 75
ACCESSING THE BATTERY 75
REMOVING COMPLETELY 75
CHECKING THE ELECTROLYTE LEVEL 75
RECHARGING THE BATTERY 76
INSTALLING THE BATTERY 77
CHANGING FUSES 77
ELECTRICAL SYSTEM 78
PLEASE NOTE:
- This is the SAME exact manual used by the dealers to FIX your vehicle.
- This can be all yours in the next 2 minutes as you will be taken to the download page after payment.
- Need any other service / repair / parts manual, please feel free to contact [email protected] . We still have thousands of manuals unlisted
Dennis Briar –
This is my first time ever buying a product here and I must say I love.
Zain Bentlee –
It’s definitely the best in the market. It provides enough information without overwhelming new students to this topic.