APRILIA Scarabeo 50 2T2006 Instruction manual

www.serviceaprilia.com
workshopmanual
Scarabeo 50 2T (PA C421M)
1315 6
01/2006-00
8104991 UK

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Scarabeo 50 2T
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PA C421M
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UPDATE 2

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SUMMARY
2.1. INTRODUCTION ............................................................................................................................................. 3
2.1.1. FOREWORD.......................................................................................................................................... 3
2.1.2. REFERENCE MANUALS....................................................................................................................... 4
2.1.3. VEHICLE IDENTIFICATION .................................................................................................................. 5
2.1.4. SPECIFICATIONS ................................................................................................................................. 6
2.1.5. RUNNING-IN.......................................................................................................................................... 8
2.1.6. LUBRICANT TABLE............................................................................................................................... 9
2.2. SCHEDULED MAINTENANCE...................................................................................................................... 10
2.2.1. SCHEDULED MAINTENANCE CHART............................................................................................... 10
2.2.2. MIXER OIL ........................................................................................................................................... 11
2.2.3. ADJUSTING THE REAR BRAKE......................................................................................................... 12
2.3. ENGINE......................................................................................................................................................... 13
2.3.1. REMOVING THE 50 2S ENGINE ........................................................................................................ 13
2.3.2. INSTALLING THE 50 2S ENGINE ....................................................................................................... 20
2.4. FUEL FEED SYSTEM ................................................................................................................................... 26
2.4.1. FUEL SUPPLY SYSTEM DIAGRAM.................................................................................................... 26
2.4.2. REMOVING THE FUEL AND MIXER OIL TANKS............................................................................... 27
2.5. CHASSIS....................................................................................................................................................... 33
2.5.1. REMOVING THE SEAT ....................................................................................................................... 33
2.5.2. REMOVING THE PASSENGER GRAB HANDLE................................................................................ 34
2.5.3. REMOVING THE TAIL LIGHT ............................................................................................................. 36
2.5.4. REMOVING THE BATTERY ................................................................................................................ 38
2.5.5. REMOVING THE LOWER SHIELD ..................................................................................................... 40
2.5.6. REMOVING THE EXHAUST SYSTEM ................................................................................................ 42
2.6. ELECTRIC SYSTEM ..................................................................................................................................... 44
2.6.1. WIRING DIAGRAM .............................................................................................................................. 44

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Scarabeo 50 2T
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2.1. INTRODUCTION
2.1.1. FOREWORD
This manual provides the information required for normal servicing.
This publication is intended for use by aprilia Dealers and their qualified mechanics; many concepts have been omitted
on purpose as their inclusion would be superfluous. Since complete mechanical explanations have not been included in
this manual, the reader must be familiar with basic notions of mechanics, as well as with basic repair procedures.
Without such familiarity, repairs and checks could be ineffective and even hazardous. Since the repair and vehicle check
instructions are not exhaustive, special care must be taken to avoid damage and injury. To ensure maximum customer
satisfaction with the vehicle, aprilia s.p.a. continuously improves its products and their documentation. The main
technical modifications and changes in repair procedures are communicated to all aprilia dealers and agencies
worldwide. Such modifications will be entered in subsequent editions of the manual. Should you need assistance or
clarifications about the inspection and repair procedures, please contact the aprilia SERVICE DEPT., they will be glad to
give you any information on the matter, or supply you with any detail on updates and technical changes applied to the
vehicle.
aprilia s.p.a. reserves the right to make changes to its products at any time, barring any such changes as may alter the
essential features of a product as specified in the relevant manual.
All rights of storage using electronic means, reproduction and total or partial adaptation, whatever the means adopted,
are reserved in all countries.
Third parties' products are only mentioned for information purposes, and constitute no engagement.
aprilia s.p.a. is not liable in any way for the performance or use of these products.
First edition: January 2006
Produced and printed by:
VALLEY FORGE DECA
Ravenna, Modena, Torino
DECA S.r.l.
via Vincenzo Giardini, 11
48022 Lugo (RA) - Italy
Tel. +39 - 0545 216611
Fax +39 - 0545 216610
E-mail: [email protected]
www.vftis.com
On behalf of:
aprilia s.p.a.
via G. Galilei, 1
30033 Noale (VE) - Italy
Tel. +39 – (0)41 58 29 111
Fax +39 – (0)41 58 29 190
www.aprilia.com
www.serviceaprilia.com

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2.1.2. REFERENCE MANUALS
SPARE PARTS CATALOGUE
aprilia part# (description)
5415
OWNER'S MANUAL
aprilia part# (description)
8202447
8202453
8202454
WORKSHOP MANUAL
SCARABEO 50 4S (PA C373M) – 100 4S (PA M226M) – 50 2S (APRILIA ENGINE) MY03
aprilia part# (description)
8140601
8140602
CD FOR THE NETWORK - CHASSIS
SCARABEO 50 4S (PA C373M) – 100 4S (PA M226M) – 50 2S (APRILIA ENGINE) MY03
aprilia part# (description)
8CM0011
WORKSHOP MANUAL - SCARABEO 502S/50-100 4S MY 05
aprilia part# (description)
8104990
8104991
CD FOR THE NETWORK - CHASSIS SCARABEO 502S/50-100 4S MY 05
aprilia part# (description)
8CM104

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2.1.3. VEHICLE IDENTIFICATION
POSITION OF THE SERIAL NUMBERS
These numbers are necessary for the registration of the
vehicle.
NOTE Do not alter the identification numbers if you do not
want to incur severe penal and administrative sanctions; in
particular, altering the frame number voids the warranty.
FRAME NUMBER
The frame number is stamped on the frame central tube. To
be able to read it, it is necessary to remove the cover (1).
ENGINE NUMBER
The engine number is stamped near the lower support of the
rear shock absorber.

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2.1.4. SPECIFICATIONS
DIMENSIONS
Max. length 1875 mm (73.82 in.)
Max. width (at brake levers) 710 mm (27.95 in.)
Max. height (at rear-view mirrors) 1270 mm (50 in.)
Seat height 700 mm (27.56)
Wheelbase 1245 mm (49.01 in.)
Minimum ground clearance 145 mm (5.71 in.)
Loadless weight (in running order) 91 kg (200.62 lb)
ENGINE
Model PA C421M
Number of cylinders horizontal single-cylinder
Total displacement 49 cu cm (3 cu in)
Bore / stroke 40.0 mm /39.3 mm (1.57 in /1.54 in).
Compression ratio (9.9 ± 0.5) : 1
Starting electric + kick starter
Clutch centrifugal
Cooling system forced air
TRANSMISSION
Converter Stepless automatic converter
Primary V belt
Ratios Minimum for stepless gearbox 3.07
Maximum for stepless gearbox 1.18
Final gears
CAPACITIES
Fuel (including reserve) 7 litres (12.94 gal)
Fuel reserve 1 litres (0.26 gal)
Transmission fluid 130 cu cm (7.93 gal)
Mixer oil (reserve included) 1.5 litres (3.96 gal)
Mixer oil reserve 0.60 litres (0.16 gal)
Seat no. 1 (2 in the countries where passenger is allowed)
Vehicle max. load (rider + passenger + luggage) 180 Kg (396.83 lb) (in the countries where a passenger is
allowed)
CARBURETTOR
Model Dell’Orto PHVA 17.5
FUEL SUPPLY
Fuel Unleaded premium fuel according to the DIN 51 607 (4
Stars), min. O.N. 95 (RON) and 85 (MON)
FRAME
Type Split single beam double-cradle frame
SUSPENSIONS
Front hydraulically operated telescopic fork
Travel 89 mm (3.50 in.)
Rear hydraulic monoshock
Travel 74 mm (2.91 in.)
BRAKES
Front Disc Ø 220 mm (8.66 in)
Rear Ø 140 mm (5.51 in.)
WHEELS
Rims alloy
Front 1.60 x 16"
Rear 1.85 x 16"

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TYRES
Front 2.50 x 16” – 42J
SAVA MC 26 CAPRI 46M REINF
Standard inflating pressure (front) 190 kPa (1.9 bar)
Inflation pressure with passenger (in the countries where
this is allowed)
190 kPa (1.9 bar)
Rear 2.75 x 16” – 46J
SAVA MC 26 CAPRI 52M REINF
Standard inflating pressure (rear) 220 kPa (2.2 bar)
Inflation pressure with passenger (in the countries where
this is allowed)
230 kPa (2.3 bar)
IGNITION
Type C.D.I. control unit
Spark advance 20°
Standard spark plug CHAMPION RN2C
Spark plug Electrodes gap 0.6 ±0.05 mm (0.020 ± 0.002 in.)
Engine idling rpm 1800 ± 100 rpm
ELECTRICAL SYSTEM
Battery 12 V – 4 Ah
Fuse 70 W
Generator (with permanent magnet) 12 V - 70 W
Low beam/high beam bulb 12 V - 35/35 W
Parking light bulb 12 V - 5 W
Direction indicator bulbs 12 V – 10 W
Parking light bulb/rear stoplight 12 V - 5/21 W
Number plate bulb 12 V - 5 W
Instrument panel lighting bulbs 12 V - 1.2 W
High beam warning light 12 V - 1.2 W
Direction indicator warning light 12 V - 3 W
Mixer oil reserve light 12 V - 1.2 W

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2.1.5. RUNNING-IN
After the first 500 km (312 mi), 1000 km (625 mi), carry out
the checks indicated in the column “After running-in” of
SCHEDULED MAINTENANCE INTERVALS CHART, see
(SCHEDULED MAINTENANCE CHART), in order to avoid
hurting yourself or other people and/or damaging the
vehicle.
Correct engine running-is essential to ensuring proper
performance and durability.
Twisty, hilly roads are ideal for an effective running-in of
engine, suspensions and brakes.
For the first 500 km (312 mi), keep to the following
indications:
0-100 km (0-62 mi)
Until you have covered the first 100 km (62 mi), use the
brakes gently and avoid harsh, prolonged braking. This will
help the brake pads bed in properly against the brake discs.
0-300 km (0-187 mi)
Do not keep the throttle twistgrip open for more than half its
travel for too long.
300-500 km (187-312 mi) - 300-1000 km (187-625 mi)
Do not keep the throttle twistgrip open for more than 3/4ths
of its travel for too long.
STOPPING
If possible, avoid stopping abruptly, slowing down suddenly
and braking at the last moment.
Release the throttle grip (pos. A) and gradually put on the
brakes to stop the vehicle.
If you need to stop only briefly, keep at least one brake
applied.

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2.1.6. LUBRICANT TABLE
LUBRICANT PRODUCT
Transmission fluid RECOMMENDED: F.C., SAE 75W – 90 or GEAR SYNTH, SAE
75W - 90.
As an alternative to recommended fluids, top brand oils meeting or
exceeding A.P.I. GL-4 specifications can be used.
Mixer oil RECOMMENDED: GREEN HIT 2 or CITY 2T.
As an alternative to recommended oils, top brand oils meeting or exceeding
ISO-L-ETC++, A.P.I.TC ++ specifications can be used.
Front fork fluid RECOMMENDED: F.A. 5W or F.A. 20W.
When you wish to obtain an intermediate response between those offered
by F.A. 5W and F.A. 20W oils or FORK 5W and
FORK 20W, you may mix the different products as follows:
SAE 10W = F.A. 5W 67% of volume + F.A. 20W 33% of volume.
= FORK 5W 67% of volume + FORK 20W 33%
of volume.
SAE 15W = F.A. 5W 33% of volume + F.A. 20W 67% of volume.
= FORK 5W 33% of volume + FORK 20W 67%
of volume.
Bearings and other lubrication points RECOMMENDED: AUTOGREASE MP or GREASE 30.
As an alternative to recommended grease, use top brand rolling bearing
grease that will resist a temperature range of -30°C +140°C (-22°F +284°F),
with dropping point 150°C 230°C (302°F 446°F), high corrosion protection,
good resistance to water and oxidisation.
Battery terminals Use neutral grease or Vaseline.
Brake fluid RECOMMENDED: F.F DOT 5 (DOT 4 compatible) or BRAKE
5.1, DOT 5 (DOT 4 compatible).
DANGER
Use new brake fluid only. Do not mix different makes or types
of oil without having checked bases compatibility.
Coolant DANGER
Use only antifreeze and anticorrosive without nitrite, ensuring
protection at -35°C (-31 °F) at least.
RECOMMENDED: ECOBLU -40°C (-40°F) or COOL.