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APRILIA SCARABEO 500 Workshop Repair Manual 2005

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🏷️ Basic Information Identification Make: Aprilia Model: Scarabeo 500 Year: 2005 Codes Internal Model Code: AP8152833 👋 Introduction Market Position Segment: Premium Maxi-Scooter Target Audience: Riders seeking performance, comfort, and practicality for urban commuting and longer journeys. Also targeted at independent workshops and DIY enthusiasts. Competitive Analysis Key Competitors 2005: Yamaha TMAX 500, Suzuki Burgman 400/650, Honda Silver Wing 600. Key Features Engine Type: Single-cylinder, four-stroke, liquid-cooled. Chassis Design: Steel underbone frame providing rigidity and stability. Braking System Highlight: Often equipped with powerful front and rear disc brakes, potentially with ABS as an option. Comfort Features: Spacious seating, generous legroom, and aerodynamic fairing for rider comfort. Practicality: Under-seat storage and often a glove compartment for everyday utility. 📋 Manual Details Coverage Areas Markets Covered: Global (primarily European and North American specifications reflected) Page Count Estimated Pages: 350-450 Manual Type Type: Workshop Service and Repair Manual Language Language: English Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Engine: Comprehensive disassembly, assembly, diagnostics, and repair of the 500cc engine and its components. Transmission: CVT (Continuously Variable Transmission) maintenance, repair, belt replacement, clutch assembly. Fuel System: Fuel injection system (EFI), fuel pump, injectors, fuel filter replacement, pressure testing. Cooling System: Radiator, coolant, water pump, thermostat, fan assembly testing and replacement. Electrical System: Battery, charging system (stator, regulator/rectifier), ignition system, lighting, starter motor, wiring diagrams, ECU diagnostics. Braking System: Hydraulic brake system, brake pads, discs, calipers, master cylinders, brake fluid replacement, bleeding procedures, ABS (if equipped). Suspension: Front forks (telescopic), rear shock absorbers, linkage maintenance, spring preload adjustment. Steering: Handlebar assembly, steering stem bearings, alignment. Chassis And Bodywork: Frame, fairings, seat assembly, storage compartment, panels, fasteners. Procedures Included Scheduled Maintenance: Detailed service intervals for oil changes, filter replacements, valve adjustments, spark plugs, and drive belt inspection/replacement. Troubleshooting: Systematic diagnostic procedures for common and uncommon issues, symptom-based troubleshooting guides. Repair Procedures: Step-by-step instructions for major component overhauls and repairs, including engine rebuilds. Disassembly And Assembly: Complete guides for dismantling and reassembling all major vehicle systems. Wiring Diagrams: Comprehensive, high-resolution electrical wiring schematics for all systems. Technical Depth Depth Level: Professional/Dealership Level. Covers everything from basic maintenance to full engine and transmission rebuilds, including advanced electrical diagnostics. 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text content for quick information retrieval. Print Quality Resolution: High-resolution for clear viewing of text and diagrams. Scalability: Printable pages for workshop use. Binding Type Original Binding: Typically spiral-bound or perfect-bound for professional workshop manuals. Paper Type Original Paper: Heavy-duty, glossy paper to withstand workshop conditions. ⚙️ Engine Specifications Primary Engine Engine Type: Single-cylinder, four-stroke, liquid-cooled, DOHC, 4 valves Displacement: 460 cc (approx.) Bore X Stroke: 92 mm x 69 mm (typical for this engine family) Compression Ratio: 10.5:1 (typical) Ignition System: Electronic ignition with variable advance Lubrication: Wet sump, forced lubrication Performance Horsepower: Approx. 32-35 HP at 7000 RPM (varies slightly by market and specific tuning) Torque: Approx. 37-40 Nm at 5500 RPM (varies slightly) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) - typically Keihin or similar Fuel Type: Unleaded Gasoline (95 RON recommended) Fuel Tank Capacity: Approx. 12.5 Liters Emission Control Emission Standard: Euro 2 / Euro 3 (depending on market 🔧 Transmission Standard Type: Automatic CVT (Continuously Variable Transmission) with dry clutch Features Gear Reduction: Variable (automatic) Clutch Type: Automatic centrifugal dry clutch Fluid Specifications Transmission Oil: SAE 80W-90 API GL-4 Gear Oil (for final drive) / Scooter Gear Oil (for CVT housing if separate) 📐 Dimensions Exterior Length: Approx. 2230 mm Width: Approx. 780 mm Height: Approx. 1450 mm (seat height) Weights Dry Weight: Approx. 200-215 kg (depending on equipment) Gross Vehicle Weight: Approx. 360 kg Cargo Under Seat Storage: Sufficient to hold one full-face helmet and some smaller items. 🛡️ Safety Features Ratings ABS Availability: Optional (check specific model variant) Active Features Braking System Type: Dual Hydraulic Disc Brakes (Front), Single Hydraulic Disc Brake (Rear) Lighting: Halogen Headlight, LED Taillight, Turn Signals. Passive Features Frame Construction: High-tensile steel, providing good crash protection. Mirrors: Large, adjustable mirrors for enhanced rear visibility. 💡 Technology Features Infotainment Instrument Cluster: Digital and analog combination display: speedometer, tachometer, fuel gauge, odometer, trip meter, coolant temperature warning light, oil pressure warning light. Driver Assistance ABS: Optional Anti-lock Braking System (ABS) available on certain models, enhancing safety during braking. Connectivity Charging Port: Typically includes a 12V accessory socket for charging devices. 🔧 Maintenance Service Intervals Engine Oil Change: Every 5,000 - 6,000 km or annually, whichever comes first. Oil Filter Replacement: At every engine oil change. Air Filter Cleaning/Replacement: Inspect every 5,000 km, replace as needed or every 10,000-15,000 km. Spark Plug Replacement: Every 10,000 - 12,000 km. Cvt Belt Inspection/Replacement: Inspect every 10,000 km, replace every 20,000 km or as wear dictates. Valve Clearance Check: Every 10,000 - 15,000 km. Fluid Specifications Engine Oil Type: SAE 10W-40...
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APRILIA SCARABEO 500 Workshop Repair Manual 2005
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
Scarabeo 500
Year:
2005
Codes
Internal Model Code:
AP8152833
👋 Introduction
Market Position
Segment:
Premium Maxi-Scooter
Target Audience:
Riders seeking performance, comfort, and practicality for urban commuting and longer journeys. Also targeted at independent workshops and DIY enthusiasts.
Competitive Analysis
Key Competitors 2005:
Yamaha TMAX 500, Suzuki Burgman 400/650, Honda Silver Wing 600.
Key Features
Engine Type:
Single-cylinder, four-stroke, liquid-cooled.
Chassis Design:
Steel underbone frame providing rigidity and stability.
Braking System Highlight:
Often equipped with powerful front and rear disc brakes, potentially with ABS as an option.
Comfort Features:
Spacious seating, generous legroom, and aerodynamic fairing for rider comfort.
Practicality:
Under-seat storage and often a glove compartment for everyday utility.
📋 Manual Details
Coverage Areas
Markets Covered:
Global (primarily European and North American specifications reflected)
Page Count
Estimated Pages:
350-450
Manual Type
Type:
Workshop Service and Repair Manual
Language
Language:
English
Format
Format:
Digital Download (PDF)
📖 Manual Coverage
Systems Covered
Engine:
Comprehensive disassembly, assembly, diagnostics, and repair of the 500cc engine and its components.
Transmission:
CVT (Continuously Variable Transmission) maintenance, repair, belt replacement, clutch assembly.
Fuel System:
Fuel injection system (EFI), fuel pump, injectors, fuel filter replacement, pressure testing.
Cooling System:
Radiator, coolant, water pump, thermostat, fan assembly testing and replacement.
Electrical System:
Battery, charging system (stator, regulator/rectifier), ignition system, lighting, starter motor, wiring diagrams, ECU diagnostics.
Braking System:
Hydraulic brake system, brake pads, discs, calipers, master cylinders, brake fluid replacement, bleeding procedures, ABS (if equipped).
Suspension:
Front forks (telescopic), rear shock absorbers, linkage maintenance, spring preload adjustment.
Steering:
Handlebar assembly, steering stem bearings, alignment.
Chassis And Bodywork:
Frame, fairings, seat assembly, storage compartment, panels, fasteners.
Procedures Included
Scheduled Maintenance:
Detailed service intervals for oil changes, filter replacements, valve adjustments, spark plugs, and drive belt inspection/replacement.
Troubleshooting:
Systematic diagnostic procedures for common and uncommon issues, symptom-based troubleshooting guides.
Repair Procedures:
Step-by-step instructions for major component overhauls and repairs, including engine rebuilds.
Disassembly And Assembly:
Complete guides for dismantling and reassembling all major vehicle systems.
Wiring Diagrams:
Comprehensive, high-resolution electrical wiring schematics for all systems.
Technical Depth
Depth Level:
Professional/Dealership Level. Covers everything from basic maintenance to full engine and transmission rebuilds, including advanced electrical diagnostics.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text content for quick information retrieval.
Print Quality
Resolution:
High-resolution for clear viewing of text and diagrams.
Scalability:
Printable pages for workshop use.
Binding Type
Original Binding:
Typically spiral-bound or perfect-bound for professional workshop manuals.
Paper Type
Original Paper:
Heavy-duty, glossy paper to withstand workshop conditions.
⚙️ Engine Specifications
Primary Engine
Engine Type:
Single-cylinder, four-stroke, liquid-cooled, DOHC, 4 valves
Displacement:
460 cc (approx.)
Bore X Stroke:
92 mm x 69 mm (typical for this engine family)
Compression Ratio:
10.5:1 (typical)
Ignition System:
Electronic ignition with variable advance
Lubrication:
Wet sump, forced lubrication
Performance
Horsepower:
Approx. 32-35 HP at 7000 RPM (varies slightly by market and specific tuning)
Torque:
Approx. 37-40 Nm at 5500 RPM (varies slightly)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) - typically Keihin or similar
Fuel Type:
Unleaded Gasoline (95 RON recommended)
Fuel Tank Capacity:
Approx. 12.5 Liters
Emission Control
Emission Standard:
Euro 2 / Euro 3 (depending on market
🔧 Transmission
Standard
Type:
Automatic CVT (Continuously Variable Transmission) with dry clutch
Features
Gear Reduction:
Variable (automatic)
Clutch Type:
Automatic centrifugal dry clutch
Fluid Specifications
Transmission Oil:
SAE 80W-90 API GL-4 Gear Oil (for final drive) / Scooter Gear Oil (for CVT housing if separate)
📐 Dimensions
Exterior
Length:
Approx. 2230 mm
Width:
Approx. 780 mm
Height:
Approx. 1450 mm (seat height)
Weights
Dry Weight:
Approx. 200-215 kg (depending on equipment)
Gross Vehicle Weight:
Approx. 360 kg
Cargo
Under Seat Storage:
Sufficient to hold one full-face helmet and some smaller items.
🛡️ Safety Features
Ratings
ABS Availability:
Optional (check specific model variant)
Active Features
Braking System Type:
Dual Hydraulic Disc Brakes (Front), Single Hydraulic Disc Brake (Rear)
Lighting:
Halogen Headlight, LED Taillight, Turn Signals.
Passive Features
Frame Construction:
High-tensile steel, providing good crash protection.
Mirrors:
Large, adjustable mirrors for enhanced rear visibility.
💡 Technology Features
Infotainment
Instrument Cluster:
Digital and analog combination display: speedometer, tachometer, fuel gauge, odometer, trip meter, coolant temperature warning light, oil pressure warning light.
Driver Assistance
ABS:
Optional Anti-lock Braking System (ABS) available on certain models, enhancing safety during braking.
Connectivity
Charging Port:
Typically includes a 12V accessory socket for charging devices.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 5,000 - 6,000 km or annually, whichever comes first.
Oil Filter Replacement:
At every engine oil change.
Air Filter Cleaning/Replacement:
Inspect every 5,000 km, replace as needed or every 10,000-15,000 km.
Spark Plug Replacement:
Every 10,000 - 12,000 km.
Cvt Belt Inspection/Replacement:
Inspect every 10,000 km, replace every 20,000 km or as wear dictates.
Valve Clearance Check:
Every 10,000 - 15,000 km.
Fluid Specifications
Engine Oil Type:
SAE 10W-40 API SG, SH, SJ or higher (Synthetic blend or full synthetic recommended)
Engine Oil Capacity:
Approx. 1.6 Liters (including filter)
Coolant Type:
Ethylene Glycol based coolant, 50/50 mix with distilled water (check Aprilia specifications)
Brake Fluid Type:
DOT 4 Hydraulic Brake Fluid
Known Issues
Common Wear Items:
CVT belt, variator rollers, voltage regulator, water pump seal.
Electrical Gremlins:
Some owners report minor electrical issues with aging wiring or connectors, often exacerbated by moisture.
Performance Loss:
Can sometimes be attributed to worn variator rollers, dirty fuel injectors, or clogged air filters.
📚 Vehicle History
Brand Heritage
Brand Focus:
Aprilia is an Italian manufacturer renowned for its sport motorcycles and scooters, often incorporating performance-oriented engineering.
Model Evolution
Scarabeo Lineage:
The Scarabeo line has a history of producing stylish and practical scooters, with the 500cc model representing the pinnacle of performance and touring capability within the range.
Production
Production Period:
The Scarabeo 500 was produced for several years, with the 2005 model representing a key iteration of this engine and platform.
Manufacturing Location:
Primarily Italy (Aprilia manufacturing facilities).
🏆 Awards & Recognition
Recognitions
Awards And Accolades:
While specific awards for the 2005 Scarabeo 500 are not widely documented, the Scarabeo line has historically been praised for its blend of style, performance, and comfort in the maxi-scooter segment.
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