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Aprilia Scarabeo 500 2003-2006 WSM Service Manual Repair

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🏷️ Basic Information Identification Make: Aprilia Model: Scarabeo 500 Model Years Covered: 2003, 2004, 2005, 2006 👋 Introduction Market Position Vehicle Class: Maxi-scooter, urban commuter, light touring Target Audience: Riders seeking practicality, comfort, and performance in a scooter for city and occasional longer journeys Competitive Analysis Key Competitors: Suzuki Burgman 400, Yamaha Majesty 400, Honda Silver Wing 500 Key Features Design Philosophy: European styling, comfortable ergonomics, strong performance for its class Practicality: Generous under-seat storage, comfortable seating for rider and passenger 📋 Manual Details Coverage Areas Primary Coverage: Comprehensive service, repair, and maintenance Page Count Estimated Page Count: Approximately 400-600 pages (typical for WSM) Manual Type Type: Workshop Service Manual (WSM) Language Language: English Format Format: Digital (PDF), potentially printed 📖 Manual Coverage Systems Covered Engine: Disassembly, assembly, inspection, troubleshooting, performance tuning Fuel System: Fuel injection system, fuel pump, injectors, fuel filter, fuel lines Ignition System: Ignition coils, spark plugs, ECU control, timing Cooling System: Radiator, coolant pump, thermostat, hoses, fan operation Exhaust System: Muffler, catalytic converter, exhaust manifold, lambda sensor Transmission Drive: CVT (Continuously Variable Transmission) maintenance, belt replacement, clutch assembly Brakes: Front and rear brake systems, hydraulic lines, calipers, master cylinders, bleeding procedures Suspension: Front telescopic forks, rear shock absorber, linkage (if applicable), spring rates, damping adjustments Steering: Handlebar assembly, steering head bearings, fork linkages Electrical System: Wiring diagrams, battery, charging system (stator, regulator/rectifier), lighting, starter motor, horn Lighting System: Headlight, taillight, turn signals, brake lights, dashboard illumination, bulb specifications Instrumentation: Speedometer, tachometer, fuel gauge, warning lights, diagnostic indicators Bodywork Chassis: Frame inspection, body panel removal/installation, fairings, seat, storage compartment Wheels Tires: Wheel bearing inspection, tire pressure recommendations, wheel removal/installation Frame And Body: Frame integrity checks, body panel alignment, fasteners Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug service, air filter cleaning/replacement, chain adjustment (if applicable) Troubleshooting: Diagnostic flowcharts, symptom-based troubleshooting, common fault identification Repair Procedures: Step-by-step instructions for component disassembly, repair, and reassembly Diagnostics: Fault code interpretation, electrical testing, sensor testing Engine Rebuild: Detailed instructions for engine teardown, parts inspection, and reassembly Suspension Service: Fork seal replacement, shock absorber service Brake System Service: Brake fluid flushing and bleeding, pad and disc replacement Electrical Troubleshooting: Component testing, wiring harness diagnostics, connector inspection Calibration Adjustments: Throttle cable adjustment, idle speed setting (if applicable) Technical Depth Depth: In-depth, professional-level repair and maintenance Detail Level: Includes specifications, tolerances, torque values, and detailed diagrams 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Searchability: Searchable text content for quick information retrieval Print Quality Print Readability: High-resolution, clear text and diagrams suitable for printing Binding Type Binding: N/A (for digital format); typically coil-bound or perfect-bound for printed versions Paper Type Paper Quality: N/A (for digital format); professional-grade paper for printed manuals ⚙️ Engine Specifications Primary Engine Engine Type: Single-cylinder, four-stroke, liquid-cooled Displacement: 493 cc (approximate) Bore X Stroke: 93.0 mm x 73.3 mm (typical for this engine family) Valve Train: SOHC, 4 valves Performance Horsepower: Approx. 35-40 HP (at crankshaft) Torque: Approx. 40-45 Nm (at crankshaft) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded gasoline (91 octane or higher recommended) Emission Control: Catalytic converter, Lambda sensor (oxygen sensor) 🔧 Transmission Standard Transmission Type: Automatic CVT (Continuously Variable Transmission) Features Clutch Type: Automatic centrifugal clutch Final Drive: Belt drive to rear wheel via CVT and reduction gears 📐 Dimensions Exterior Length: Approx. 2200 mm Width: Approx. 800 mm Height: Approx. 1400 mm (seat height) Weights Dry Weight: Approx. 185-195 kg Gross Vehicle Weight Rating: Approx. 360 kg Cargo Under Seat Storage: Sufficient for one full-face helmet and additional items 🛡️ Safety Features Ratings Crash Safety: Motorcycle-specific safety standards, no formal car-like crash ratings Active Features Braking System: Dual disc front brakes, single disc rear brake. Likely ABS on some models/markets. Lighting: Halogen headlight, LED taillight/brake light (market dependent) Passive Features Frame Construction: Steel tube frame for rigidity and impact absorption Riding Position: Upright and comfortable, providing good rider visibility 💡 Technology Features Infotainment Instrument Cluster: Analog speedometer and tachometer, digital odometer, fuel gauge, clock, and various indicator lights. Driver Assistance ABS Availability: ABS was an optional feature on some Scarabeo 500 models, depending on market and specific trim. Connectivity Connectivity Features: No advanced connectivity features (Bluetooth, smartphone integration) typically found on modern vehicles. 🔧 Maintenance Service Intervals Engine Oil Change: Every 5,000 km or 6 months, whichever comes first. Oil Filter Replacement: Every 10,000 km or 12 months (concurrent with oil change). Air Filter Service: Inspect every 5,000 km, clean/replace as needed based on conditions. Spark Plug Replacement: Every 10,000 km or as per inspection. Cvt Belt Inspection: Inspect at 10,000 km, replace typically around 20,000 km or when worn. Coolant Change: Every 2 years or 20,000 km. Brake Fluid Change: Every 2 years. Fluid Specifications Engine Oil Type: Synthetic SAE 10W-40, API SG or higher, JASO...
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Aprilia Scarabeo 500 2003-2006 WSM Service Manual Repair
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
Scarabeo 500
Model Years Covered:
2003, 2004, 2005, 2006
👋 Introduction
Market Position
Vehicle Class:
Maxi-scooter, urban commuter, light touring
Target Audience:
Riders seeking practicality, comfort, and performance in a scooter for city and occasional longer journeys
Competitive Analysis
Key Competitors:
Suzuki Burgman 400, Yamaha Majesty 400, Honda Silver Wing 500
Key Features
Design Philosophy:
European styling, comfortable ergonomics, strong performance for its class
Practicality:
Generous under-seat storage, comfortable seating for rider and passenger
📋 Manual Details
Coverage Areas
Primary Coverage:
Comprehensive service, repair, and maintenance
Page Count
Estimated Page Count:
Approximately 400-600 pages (typical for WSM)
Manual Type
Type:
Workshop Service Manual (WSM)
Language
Language:
English
Format
Format:
Digital (PDF), potentially printed
📖 Manual Coverage
Systems Covered
Engine:
Disassembly, assembly, inspection, troubleshooting, performance tuning
Fuel System:
Fuel injection system, fuel pump, injectors, fuel filter, fuel lines
Ignition System:
Ignition coils, spark plugs, ECU control, timing
Cooling System:
Radiator, coolant pump, thermostat, hoses, fan operation
Exhaust System:
Muffler, catalytic converter, exhaust manifold, lambda sensor
Transmission Drive:
CVT (Continuously Variable Transmission) maintenance, belt replacement, clutch assembly
Brakes:
Front and rear brake systems, hydraulic lines, calipers, master cylinders, bleeding procedures
Suspension:
Front telescopic forks, rear shock absorber, linkage (if applicable), spring rates, damping adjustments
Steering:
Handlebar assembly, steering head bearings, fork linkages
Electrical System:
Wiring diagrams, battery, charging system (stator, regulator/rectifier), lighting, starter motor, horn
Lighting System:
Headlight, taillight, turn signals, brake lights, dashboard illumination, bulb specifications
Instrumentation:
Speedometer, tachometer, fuel gauge, warning lights, diagnostic indicators
Bodywork Chassis:
Frame inspection, body panel removal/installation, fairings, seat, storage compartment
Wheels Tires:
Wheel bearing inspection, tire pressure recommendations, wheel removal/installation
Frame And Body:
Frame integrity checks, body panel alignment, fasteners
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, spark plug service, air filter cleaning/replacement, chain adjustment (if applicable)
Troubleshooting:
Diagnostic flowcharts, symptom-based troubleshooting, common fault identification
Repair Procedures:
Step-by-step instructions for component disassembly, repair, and reassembly
Diagnostics:
Fault code interpretation, electrical testing, sensor testing
Engine Rebuild:
Detailed instructions for engine teardown, parts inspection, and reassembly
Suspension Service:
Fork seal replacement, shock absorber service
Brake System Service:
Brake fluid flushing and bleeding, pad and disc replacement
Electrical Troubleshooting:
Component testing, wiring harness diagnostics, connector inspection
Calibration Adjustments:
Throttle cable adjustment, idle speed setting (if applicable)
Technical Depth
Depth:
In-depth, professional-level repair and maintenance
Detail Level:
Includes specifications, tolerances, torque values, and detailed diagrams
📊 Manual Specifications
File Format
File Type:
PDF (Portable Document Format)
Searchability:
Searchable text content for quick information retrieval
Print Quality
Print Readability:
High-resolution, clear text and diagrams suitable for printing
Binding Type
Binding:
N/A (for digital format); typically coil-bound or perfect-bound for printed versions
Paper Type
Paper Quality:
N/A (for digital format); professional-grade paper for printed manuals
⚙️ Engine Specifications
Primary Engine
Engine Type:
Single-cylinder, four-stroke, liquid-cooled
Displacement:
493 cc (approximate)
Bore X Stroke:
93.0 mm x 73.3 mm (typical for this engine family)
Valve Train:
SOHC, 4 valves
Performance
Horsepower:
Approx. 35-40 HP (at crankshaft)
Torque:
Approx. 40-45 Nm (at crankshaft)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded gasoline (91 octane or higher recommended)
Emission Control:
Catalytic converter, Lambda sensor (oxygen sensor)
🔧 Transmission
Standard
Transmission Type:
Automatic CVT (Continuously Variable Transmission)
Features
Clutch Type:
Automatic centrifugal clutch
Final Drive:
Belt drive to rear wheel via CVT and reduction gears
📐 Dimensions
Exterior
Length:
Approx. 2200 mm
Width:
Approx. 800 mm
Height:
Approx. 1400 mm (seat height)
Weights
Dry Weight:
Approx. 185-195 kg
Gross Vehicle Weight Rating:
Approx. 360 kg
Cargo
Under Seat Storage:
Sufficient for one full-face helmet and additional items
🛡️ Safety Features
Ratings
Crash Safety:
Motorcycle-specific safety standards, no formal car-like crash ratings
Active Features
Braking System:
Dual disc front brakes, single disc rear brake. Likely ABS on some models/markets.
Lighting:
Halogen headlight, LED taillight/brake light (market dependent)
Passive Features
Frame Construction:
Steel tube frame for rigidity and impact absorption
Riding Position:
Upright and comfortable, providing good rider visibility
💡 Technology Features
Infotainment
Instrument Cluster:
Analog speedometer and tachometer, digital odometer, fuel gauge, clock, and various indicator lights.
Driver Assistance
ABS Availability:
ABS was an optional feature on some Scarabeo 500 models, depending on market and specific trim.
Connectivity
Connectivity Features:
No advanced connectivity features (Bluetooth, smartphone integration) typically found on modern vehicles.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 5,000 km or 6 months, whichever comes first.
Oil Filter Replacement:
Every 10,000 km or 12 months (concurrent with oil change).
Air Filter Service:
Inspect every 5,000 km, clean/replace as needed based on conditions.
Spark Plug Replacement:
Every 10,000 km or as per inspection.
Cvt Belt Inspection:
Inspect at 10,000 km, replace typically around 20,000 km or when worn.
Coolant Change:
Every 2 years or 20,000 km.
Brake Fluid Change:
Every 2 years.
Fluid Specifications
Engine Oil Type:
Synthetic SAE 10W-40, API SG or higher, JASO MA recommended.
Engine Oil Capacity:
Approx. 1.6 - 1.8 liters (with filter change)
Coolant Type:
Ethylene glycol-based antifreeze, 50/50 mix with distilled water.
Brake Fluid Type:
DOT 4.
Known Issues
Common Wear Items:
CVT belt, brake pads, suspension bushings, starter motor brushes.
Electrical Gremlins:
Occasionally reported issues with wiring harness connections or regulator/rectifier failures, typical for many scooters of this era.
Cooling System Performance:
Ensure radiator is clean and fan operates correctly, especially in stop-and-go traffic.
📚 Vehicle History
Brand Heritage
Manufacturer Origin:
Aprilia is an Italian manufacturer, known for its sport motorcycles and scooters.
Model Evolution
Scarabeo Lineage:
The Scarabeo line has been a staple of Aprilia's scooter offerings, known for its blend of style and practicality.
Scarabeo 500 Introduction:
The 500cc variant was introduced to offer more power and touring capability compared to smaller displacement models.
Production
Production Period:
2003-2006 for this specific generation/engine configuration.
Manufacturing Location:
Primarily Italy.
🏆 Awards & Recognition
Recognitions
Industry Acclaim:
The Scarabeo 500 was generally well-received for its comfortable ride, performance, and practicality, competing effectively in the maxi-scooter segment.
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