Aprilia Scarabeo 500 Complete Workshop Service Repair Manual 2005 2006
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🏷️ Basic Information Identification Make: Aprilia Model: Scarabeo 500 Year: 2005, 2006 Product Type: Workshop Service Repair Manual 👋 Introduction Market Position Vehicle Segment: Maxi-scooter, often positioned as a stylish and comfortable urban commuter with touring capabilities. Target Audience: Commuters, urban riders, touring enthusiasts seeking a comfortable and practical scooter with significant engine power. Competitive Analysis Key Competitors: Suzuki Burgman 400/650, Yamaha Majesty 400, Honda Silver Wing 400/600, Kymco Xciting 500. Key Features Styling: Distinctive Italian design, often characterized by flowing lines and a comfortable riding position. Performance: Powerful 500cc engine offering good acceleration and comfortable highway cruising speeds. Practicality: Generous under-seat storage, comfortable ergonomics for long rides. 📋 Manual Details Coverage Areas Language: English Format: Digital Download (likely PDF) Manual Type: Comprehensive Workshop Service & Repair Manual Page Count: Not specified in product info, but typically 300-600 pages for this type of manual. 📖 Manual Coverage Systems Covered Engine: Complete engine service, disassembly, assembly, troubleshooting, diagnostics, component inspection. Fuel System: Fuel injection system, fuel pump, injectors, fuel filter, fuel lines, throttle body. Cooling System: Radiator, coolant hoses, water pump, thermostat, fan, coolant specifications. Ignition System: Spark plugs, ignition coils, ECU control of ignition timing. Exhaust System: Exhaust pipes, muffler, catalytic converter (if applicable), oxygen sensors. Transmission Drivetrain: Automatic CVT (Continuously Variable Transmission) service, belt replacement, clutch assembly, variator, torque converter, final drive. Brakes: Front and rear brake systems, hydraulic lines, master cylinders, calipers, brake pads, brake discs, bleeding procedures, ABS (if equipped). Suspension: Front fork service, rear shock absorber replacement, linkage maintenance, suspension geometry. Steering: Handlebar assembly, steering stem, bearings, tie rods (if applicable). Electrical System: Battery, charging system (alternator/stator, regulator/rectifier), starter motor, lighting system (headlights, taillights, turn signals), wiring diagrams, fuses, relays, ECU. Instrumentation: Dashboard, speedometer, tachometer, warning lights, sensor diagnostics. Bodywork Chassis: Fairings, body panels, seat, storage compartments, chassis inspection, frame repairs. Wheels Tires: Wheel bearing service, tire pressure specifications, tire replacement, wheel balancing. Procedures Included Maintenance: Scheduled maintenance (oil changes, filter replacements, spark plug replacement, brake fluid changes, coolant changes, drive belt inspection/replacement), lubrication points, torque specifications for routine maintenance. Troubleshooting: Diagnostic charts, symptom-based troubleshooting for common issues, electrical system diagnostics, engine performance problems. Repair: Detailed step-by-step repair instructions for all major components and systems, including engine rebuilds, transmission overhauls, brake system repairs, electrical component replacement. Disassembly Assembly: Complete disassembly and reassembly procedures for engine, transmission, suspension, and bodywork components. Special Tools: Identification and usage of special tools required for specific repair and maintenance tasks. Technical Depth Depth: Comprehensive, covering everything from basic routine maintenance to complete engine and transmission overhauls, including detailed electrical troubleshooting with wiring diagrams. 📊 Manual Specifications File Format File Type: Digital Download (PDF) Searchability: Likely text-searchable PDF for efficient information retrieval. Printability: Printable pages for convenient workshop use. Quality: Assumed to be high-resolution scans or original digital files for clear diagrams and text. Binding Type: N/A (Digital Download) Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, single-cylinder, liquid-cooled Displacement: 460 cc (exact figure may vary slightly by region/specific model iteration) Bore X Stroke: Typically around 92 mm x 69 mm Valvetrain: SOHC, 4 valves per cylinder Performance Horsepower: Approximately 33-36 HP (24-27 kW) at peak RPM. Torque: Approximately 38-40 Nm (28-30 ft-lbs) at peak RPM. Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded gasoline, minimum 91 octane (RON+MON)/95 RON recommended. Ignition: Electronic ignition system with ECU control. 🔧 Transmission Standard Transmission Type: Automatic CVT (Continuously Variable Transmission) Drive Type: Belt drive to rear wheel Features Clutch: Automatic centrifugal clutch Variator: Variable diameter pulleys for automatic gear ratio adjustment. 📐 Dimensions Exterior Length: Approx. 2200-2250 mm (86.6-88.6 inches) Width: Approx. 750-800 mm (29.5-31.5 inches) Height: Approx. 1400-1450 mm (55.1-57.1 inches) Seat Height: Approx. 770-790 mm (30.3-31.1 inches) Cargo Underseat Storage: Sufficient for at least one full-face helmet, often with additional space. Weights Dry Weight: Approx. 180-195 kg (397-430 lbs) Wet Weight: Approx. 195-210 kg (430-463 lbs) with fluids. Max Load Capacity: Typically around 180-200 kg (397-441 lbs), including rider and cargo. 🛡️ Safety Features Ratings Crash Safety: N/A (Motorcycles/Scooters are not typically rated by agencies like NHTSA/Euro NCAP in the same way as cars. Focus is on design and component integrity). Active Features Braking System: Integral braking system often featured (e.g., linking front and rear brakes via lever application). Optional ABS was available on some models/trims. Lighting: Halogen headlight, LED or incandescent taillight and turn signals. Passive Features Chassis Design: Robust steel frame designed for stability and rider confidence. Wind Protection: Integrated fairing and windscreen providing significant wind protection for the rider. 💡 Technology Features Infotainment Dashboard Features: Analog speedometer and tachometer, LCD display for fuel level, engine temperature, odometer, trip meter, clock. Warning lights for oil, battery, high beam, turn signals. Driver Assistance ABS: Optional Anti-lock Braking System (ABS) available on some variants,...
Diagnostic charts, symptom-based troubleshooting for common issues, electrical system diagnostics, engine performance problems.
Repair:
Detailed step-by-step repair instructions for all major components and systems, including engine rebuilds, transmission overhauls, brake system repairs, electrical component replacement.
Disassembly Assembly:
Complete disassembly and reassembly procedures for engine, transmission, suspension, and bodywork components.
Special Tools:
Identification and usage of special tools required for specific repair and maintenance tasks.
Technical Depth
Depth:
Comprehensive, covering everything from basic routine maintenance to complete engine and transmission overhauls, including detailed electrical troubleshooting with wiring diagrams.
📊 Manual Specifications
File Format
File Type:
Digital Download (PDF)
Searchability:
Likely text-searchable PDF for efficient information retrieval.
Printability:
Printable pages for convenient workshop use.
Quality:
Assumed to be high-resolution scans or original digital files for clear diagrams and text.
Binding Type:
N/A (Digital Download)
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Four-stroke, single-cylinder, liquid-cooled
Displacement:
460 cc (exact figure may vary slightly by region/specific model iteration)
Bore X Stroke:
Typically around 92 mm x 69 mm
Valvetrain:
SOHC, 4 valves per cylinder
Performance
Horsepower:
Approximately 33-36 HP (24-27 kW) at peak RPM.
Torque:
Approximately 38-40 Nm (28-30 ft-lbs) at peak RPM.
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded gasoline, minimum 91 octane (RON+MON)/95 RON recommended.
Variable diameter pulleys for automatic gear ratio adjustment.
📐 Dimensions
Exterior
Length:
Approx. 2200-2250 mm (86.6-88.6 inches)
Width:
Approx. 750-800 mm (29.5-31.5 inches)
Height:
Approx. 1400-1450 mm (55.1-57.1 inches)
Seat Height:
Approx. 770-790 mm (30.3-31.1 inches)
Cargo
Underseat Storage:
Sufficient for at least one full-face helmet, often with additional space.
Weights
Dry Weight:
Approx. 180-195 kg (397-430 lbs)
Wet Weight:
Approx. 195-210 kg (430-463 lbs) with fluids.
Max Load Capacity:
Typically around 180-200 kg (397-441 lbs), including rider and cargo.
🛡️ Safety Features
Ratings
Crash Safety:
N/A (Motorcycles/Scooters are not typically rated by agencies like NHTSA/Euro NCAP in the same way as cars. Focus is on design and component integrity).
Active Features
Braking System:
Integral braking system often featured (e.g., linking front and rear brakes via lever application). Optional ABS was available on some models/trims.
Lighting:
Halogen headlight, LED or incandescent taillight and turn signals.
Passive Features
Chassis Design:
Robust steel frame designed for stability and rider confidence.
Wind Protection:
Integrated fairing and windscreen providing significant wind protection for the rider.
💡 Technology Features
Infotainment
Dashboard Features:
Analog speedometer and tachometer, LCD display for fuel level, engine temperature, odometer, trip meter, clock. Warning lights for oil, battery, high beam, turn signals.
Driver Assistance
ABS:
Optional Anti-lock Braking System (ABS) available on some variants, significantly enhancing safety during braking.
Connectivity
Diagnostics:
On-board diagnostics (OBD) capabilities for engine control unit (ECU) troubleshooting, typically accessed via a diagnostic port.
🔧 Maintenance
Service Intervals
Oil Change:
Typically every 6,000 km (3,700 miles) or annually. Consult manual for precise intervals.
Air Filter:
Inspect every 6,000 km (3,700 miles), replace as needed or at higher mileage intervals (e.g., 12,000-18,000 km).
Spark Plug:
Replace typically every 12,000 km (7,500 miles). Use specified iridium or high-quality spark plug.
Drive Belt:
Inspect for wear and tension every 12,000 km (7,500 miles), replace as recommended (often around 20,000-24,000 km or sooner if worn).
Brake Fluid:
Replace every 2 years, regardless of mileage.
Coolant:
Inspect level regularly, flush and replace every 2-3 years or as per manual. Typically uses a 50/50 mix of ethylene glycol antifreeze and distilled water.
Fluid Specifications
Engine Oil:
SAE 10W-40, API SJ/SL or higher, JASO MA/MA2 certified (for wet clutch compatibility). Capacity approx. 1.4-1.6 Liters. Specific Aprilia recommendation is crucial.
Voltage regulator/rectifier failures have been reported on some Aprilia models of this era, leading to charging issues. Battery health is critical.
Potential Engine:
Overheating if coolant system is neglected. Ensure correct coolant level and functioning fan.
📚 Vehicle History
Brand Heritage
Manufacturer:
Aprilia is an Italian manufacturer known for its performance motorcycles and scooters.
Model Evolution
Scarabeo Lineage:
The Scarabeo line, introduced in the early 1990s, is Aprilia's flagship scooter series, known for blending practicality with style and performance. The 500cc model represented a significant step up in power and capability.
Production
Manufacturing Location:
Primarily manufactured in Italy.
Key Updates 2005-2006:
These years represent a specific generation of the Scarabeo 500, likely with minor refinements or updates over earlier models. Specific technical updates would be detailed within the manual.
🏆 Awards & Recognition
Recognitions
Industry Acclaim:
While specific awards for the 2005-2006 Scarabeo 500 may not be widely publicized, the Scarabeo line is generally praised for its blend of style, comfort, and performance in the maxi-scooter segment. Expert reviews often highlight its Italian flair and capable engine.