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
)
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.

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2.2. SCHEDULED MAINTENANCE
2.2.1. SCHEDULED MAINTENANCE CHART
Component
After running-in
[500 km
(312 mi)]
Every 4000 km
(2500 mi)
or 12 months
Every 8000 km
(5000 mi) or 24
months
Battery – Clamp tightening - Electrolyte level 1 1 -
Spark plug 1 1 3
Carburettor - idling 4 1 -
Air filter 1 2 -
Throttle operation 1 1 -
Brake locking operation 1 1 -
Lighting system 1 1 -
Brake light switches - 1 -
Brake fluid - 1 -
Mixer oil Every 500 km (312 mi): 1
Headlight beam direction - operation 1 -
Spark plug cap 1 -
Wheels / tyres and inflating pressure Every month: 1
Wear of rear brake pads 1 1 -
Wear of front brake pads 1 every 2000 km (1250 mi): 1
Rear shock absorber - - 1
Bowden cables and controls 1 1 -
Converter belt - - every 12000 km
(7500 mi): 1
Steering tube bearings and steering play 1 1 -
Wheel bearings - 1 -
Brake disc 1 1 -
Brake drum 1 1 -
Clamps every 12000 km (7500 mi): 1
Vehicle operation 1 1 -
Braking systems / brake discs 1 1 -
Greasing of electric starting shafts - - 1
Greasing of rear brake cam shaft - 1 -
Brake fluid every 2 years: 3
Exhaust muffler/exhaust silencer - 1 -
Mixer / throttle operation 1 1 -
Transmission fluid 3 1 every 12000 km
(7500 mi): 1
Rear pulley pins every 12000 km (7500 mi): 3
Fork damper rod - 1 -
Mobile/fixed front belt roller every 12000 km (7500 mi): 3
Front converter rollers and guides - - 3
Wheels / tyres and inflating pressure 1 1 -
Nut, bolt, screw tightening 1 1 -
Battery terminals tightening 1 - -
Mixer oil reserve light 1 1 -
Cylinder head and cylinder - - 2
Fuel hose every 4000 km (2500 mi): 1 /every 4 years: 3
Braking system lines every 4000 km (2500 mi): 1 /every 4 years: 3
Mixer oil lines 1 1 every 2 years: 3
Clutch wear - - 1
1 = check and clean, adjust, lubricate or change, if necessary; 2 = clean; 3= change; 4= adjust.
Carry out the maintenance operations more frequently if you use the vehicle in rainy and dusty areas or on uneven
ground.
() = OPERATIONS THAT CAN BE CARRIED OUT BY THE USER

UPDATE
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2.2.2. MIXER OIL
WARNING
Using the vehicle with no mixer oil left
seriously damages the engine. In the event you
run out of mixer oil or the mixer oil hose is
removed, contact an aprilia Authorised dealer
that will bleed the system. This operation is
necessary because engine might be damaged if
running with air in the mixer oil system.
NOTE Top up mixer oil tank every 2000 km (1250 mi).
The vehicle features a control unit that manages an
electronic pump ensuring correct oil quantity for engine
lubrication; see (LUBRICANT TABLE).
The reserve is indicated by the mixer oil reserve light
on the instrument panel
To top up mixer oil proceed as follows:
•Raise the seat, see (REMOVING THE SEAT).
•Remove the cap (1).
- Mixer oil tank capacity: 1.5 l (0.39 gal)
- Mixer oil tank reserve: 0.6 l (0.16 gal)
WARNING
Do not put additives or other substances into
the oil.
If a funnel or other system is used for topping
up, make sure that it is perfectly clean.
•Top up.
WARNING
Once refuelling is over, refit plug (1) in its
correct position.
•Tighten the plug (1) and lock the seat.

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2.2.3. ADJUSTING THE REAR BRAKE
•Measure lever stroke distance before braking action is
started.
•The lever idle stroke measured at lever end shall be
about 10 mm (0.39 in).
Adjusting clearance:
•Force spring (1) to gain access to seat (2) of threaded
linkage.
•Lock threaded linkage rotation using a wrench on the
flats (2).
•Turn adjuster (3).
•Operate the brake repeatedly and verify that the wheel
is rotating freely once the brake has been released.
•Check the brake for proper operation.

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2.3. ENGINE
2.3.1. REMOVING THE 50 2S ENGINE
•To remove the crankcase, first remove the fuel tank
and mixer oil tank, see (REMOVING THE FUEL AND
MIXER OIL TANKS), the battery, see (REMOVING
THE BATTERY), the lower shield, see (REMOVING
THE LOWER SHIELD) and the exhaust, see
(REMOVING THE EXHAUST).
•Using a belt and an A-frame, support the vehicle rear
end.
•Loosen and remove the two cable guide screws.
•Loosen and remove adjuster nut and keep washer and
spring.
•Slide out rear brake cable from the front.

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•Disconnect the spark plug cap.
•Remove the rubber protection.
•Disconnect the automatic choke connector.
•Remove the clamp and disconnect generator
connector.
•Prepare a suitable support under transmission.

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•Remove rear wheel nut cap.
•Loosen and remove the rear wheel nut.
•Remove the rear wheel from the side.
•Unscrew and remove the screw.

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•Loosen and remove the screw, moving aside the
ground cable.
•Remove the starter motor with O-ring and move it
backward.
•Loosen the screw and disconnect the connector.
•Remove the starter motor.
•Loosen and remove the screw and keep the nut.

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•Fasten the shock absorber to the frame.
•Remove the tie and disconnect the vacuum hose.
•Loosen and remove the screw and remove the throttle
cable.
•Using a screwdriver, remove the oil pump plug.

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•Loosen oil pump adjuster nut.
•Loosen the key and release the peg from pulley.
•Loosen the adjuster and remove the oil pump adjuster
cable.
NOTE Perform the following operations together with
another operator.
•Working on the left side, loosen and remove the nut,
holding the pin on the opposite side.

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•Slide out pin on the right side tapping on the other side
with a rubber mallet.
•Remove the frame from the front.