APRILIA SCARABEO 500 BIKE Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Aprilia Model: Scarabeo 500 Model Generation: First Generation (pre-2008 facelift) Production Years Covered By Manual: Likely 2003-2008 (based on engine type and common manual coverage) Engine Code: M273M Engine Variant: 460cc, 1-Cylinder, 4-Stroke, Liquid-Cooled, OHC 👋 Introduction Market Position Vehicle Segment: Maxi-scooter, urban mobility, touring scooter Target Audience: Commuters, urban riders, touring enthusiasts seeking comfort and performance in a scooter format Competitive Analysis Key Competitors: Suzuki Burgman 400/650, Yamaha Majesty 400, Honda Silver Wing 400/600, Kymco Grand Dink 250/300, Piaggio Beverly 500 Key Features Design Philosophy: Italian design flair combined with practical maxi-scooter functionality Engine Power Delivery: Torquey single-cylinder engine providing strong acceleration and comfortable cruising Handling: Often praised for its stable handling and comfortable ride, bridging the gap between scooter agility and motorcycle stability Storage: Generous under-seat storage typical for maxi-scooters 📋 Manual Details Coverage Areas Manual Type: Workshop Service Repair Manual & User/Maintenance Manual Language: English (Assumed, common for international market manuals) Format: Digital (Likely PDF, indicated by 'Product Name' and description) Additional Manuals Included: User and Maintenance Manual 📖 Manual Coverage Systems Covered Engine: Complete engine assembly, lubrication, cooling, ignition, fuel injection, exhaust, internal components (piston, rings, valves, camshaft, crankshaft) Transmission: Automatic transmission (CVT), variator, clutch, final drive Chassis: Frame, front suspension (forks), rear suspension (shock absorber, swingarm), steering Brakes: Front and rear brake system components (calipers, master cylinders, brake lines, discs), hydraulic system Electrical: Wiring diagrams, starter system, charging system (alternator, battery), lighting, ignition system, instrument panel, fuel pump, fan Fuel System: Fuel tank, fuel pump, fuel lines, fuel filter, fuel injection system (ECU, injectors, sensors) Bodywork: Body panels, seat, storage compartments, fairings, trim pieces Procedures Included Maintenance: Routine inspections, oil changes, filter replacements, spark plug replacement, coolant checks and changes, brake fluid replacement, battery maintenance Troubleshooting: Diagnostic procedures for common and uncommon faults, symptom-based troubleshooting guides Repair: Detailed step-by-step repair instructions for all major and minor components, engine teardown and rebuild, transmission overhaul, suspension and brake component replacement Disassembly And Assembly: Comprehensive instructions for removing and installing all vehicle components Torque Specifications: Crucial torque values for all fasteners Technical Depth Depth: Comprehensive, covering basic to advanced repairs and diagnostics, suitable for professional technicians and experienced DIY mechanics Diagrams: Includes detailed exploded diagrams for part identification and assembly Wiring Diagrams: Full color, detailed electrical wiring schematics 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text (assumed for quality PDF manuals) Printability: Printable (assumed for workshop manuals) Print Quality Image Resolution: High resolution for clear diagrams and illustrations Text Clarity: Sharp and legible text Binding Type Binding: N/A (Digital Format) Paper Type Paper Quality: N/A (Digital Format) Page Count Estimated Page Count: 300-500 pages (typical for a comprehensive workshop manual of this era and coverage) ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, single-cylinder Engine Displacement: 460 cc Cooling System: Liquid-cooled Valve Train: OHC (Single Overhead Camshaft) Bore X Stroke: Typically around 92mm x 84mm (specific values to be confirmed in manual) Compression Ratio: Typically around 10.0:1 to 10.5:1 (specific values to be confirmed in manual) Performance Horsepower Approx: ~30-35 HP (at ~7000 rpm, actual figures vary by year/market) Torque Approx: ~40-45 Nm (at ~5500 rpm, actual figures vary by year/market) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded gasoline (RON 91 or higher) Ignition System: Electronic ignition with ECU control 🔧 Transmission Standard Type: Automatic (CVT - Continuously Variable Transmission) Drive: Belt drive to rear wheel via final reduction gears Clutch Type: Automatic centrifugal clutch Features Variator Maintenance: Includes variator roller inspection/replacement, belt inspection/replacement Final Drive Fluid: Specific gear oil required (check manual for type and interval) 📐 Dimensions Exterior Overall Length: Approx. 2190 mm (Varies slightly by specific model year) Overall Width: Approx. 770 mm (Varies slightly by specific model year) Seat Height: Approx. 795 mm (Varies slightly by specific model year) Weights Dry Weight: Approx. 185-195 kg (Varies slightly by specific model year) Fuel Tank Capacity: Approx. 14 liters (including reserve) 🛡️ Safety Features Ratings Crash Test Data: N/A for motorcycle/scooter segment in standard automotive terms; focus on component integrity and operational safety Active Features Braking System: Typically equipped with disc brakes front and rear, potentially ABS on later or higher-spec models (manual will specify) Lighting: Halogen headlamp, LED tail/brake lights (model dependent), turn signals Passive Features Frame Construction: Steel frame providing structural integrity Tires: Tubeless tires for improved puncture resistance (specific sizes in manual) 💡 Technology Features Infotainment Instrument Cluster: Digital/analog combination for speed, RPM, fuel level, coolant temperature, odometer, trip meter, clock. Warning lights for various systems. Driver Assistance ABS: Anti-lock Braking System (ABS) may be available on some models/markets; the manual will detail its operation and service. Connectivity Diagnostic Port: On-board diagnostic (OBD) port for electronic fault code reading and system analysis (specific connector type and protocol in manual). 🔧 Maintenance...
Diagnostic procedures for common and uncommon faults, symptom-based troubleshooting guides
Repair:
Detailed step-by-step repair instructions for all major and minor components, engine teardown and rebuild, transmission overhaul, suspension and brake component replacement
Disassembly And Assembly:
Comprehensive instructions for removing and installing all vehicle components
Torque Specifications:
Crucial torque values for all fasteners
Technical Depth
Depth:
Comprehensive, covering basic to advanced repairs and diagnostics, suitable for professional technicians and experienced DIY mechanics
Diagrams:
Includes detailed exploded diagrams for part identification and assembly
Wiring Diagrams:
Full color, detailed electrical wiring schematics
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text (assumed for quality PDF manuals)
Printability:
Printable (assumed for workshop manuals)
Print Quality
Image Resolution:
High resolution for clear diagrams and illustrations
Text Clarity:
Sharp and legible text
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper Quality:
N/A (Digital Format)
Page Count
Estimated Page Count:
300-500 pages (typical for a comprehensive workshop manual of this era and coverage)
⚙️ Engine Specifications
Primary Engine
Engine Type:
4-stroke, single-cylinder
Engine Displacement:
460 cc
Cooling System:
Liquid-cooled
Valve Train:
OHC (Single Overhead Camshaft)
Bore X Stroke:
Typically around 92mm x 84mm (specific values to be confirmed in manual)
Compression Ratio:
Typically around 10.0:1 to 10.5:1 (specific values to be confirmed in manual)
Performance
Horsepower Approx:
~30-35 HP (at ~7000 rpm, actual figures vary by year/market)
Torque Approx:
~40-45 Nm (at ~5500 rpm, actual figures vary by year/market)
Belt drive to rear wheel via final reduction gears
Clutch Type:
Automatic centrifugal clutch
Features
Variator Maintenance:
Includes variator roller inspection/replacement, belt inspection/replacement
Final Drive Fluid:
Specific gear oil required (check manual for type and interval)
📐 Dimensions
Exterior
Overall Length:
Approx. 2190 mm (Varies slightly by specific model year)
Overall Width:
Approx. 770 mm (Varies slightly by specific model year)
Seat Height:
Approx. 795 mm (Varies slightly by specific model year)
Weights
Dry Weight:
Approx. 185-195 kg (Varies slightly by specific model year)
Fuel Tank Capacity:
Approx. 14 liters (including reserve)
🛡️ Safety Features
Ratings
Crash Test Data:
N/A for motorcycle/scooter segment in standard automotive terms; focus on component integrity and operational safety
Active Features
Braking System:
Typically equipped with disc brakes front and rear, potentially ABS on later or higher-spec models (manual will specify)
Lighting:
Halogen headlamp, LED tail/brake lights (model dependent), turn signals
Passive Features
Frame Construction:
Steel frame providing structural integrity
Tires:
Tubeless tires for improved puncture resistance (specific sizes in manual)
💡 Technology Features
Infotainment
Instrument Cluster:
Digital/analog combination for speed, RPM, fuel level, coolant temperature, odometer, trip meter, clock. Warning lights for various systems.
Driver Assistance
ABS:
Anti-lock Braking System (ABS) may be available on some models/markets; the manual will detail its operation and service.
Connectivity
Diagnostic Port:
On-board diagnostic (OBD) port for electronic fault code reading and system analysis (specific connector type and protocol in manual).
🔧 Maintenance
Service Intervals
Engine Oil Change:
Typically every 5,000 - 7,500 km or annually (refer to manual for exact mileage/time)
Oil Filter Replacement:
At every engine oil change (refer to manual)
Air Filter Cleaning Or Replacement:
Typically every 5,000 - 10,000 km (refer to manual)
Spark Plug Replacement:
Typically every 10,000 - 15,000 km (refer to manual for specific plug type and gap)
Coolant Replacement:
Every 2-3 years or 20,000 - 30,000 km (refer to manual)
Brake Fluid Replacement:
Every 2 years (refer to manual)
Variator Belt Inspection And Replacement:
Inspection every 5,000 km, replacement typically between 15,000 - 20,000 km (refer to manual for wear limits)
Fluid Specifications
Engine Oil Type:
Semi-synthetic or fully synthetic SAE 10W-40 or 15W-50 motorcycle specific oil (API SG/SH/SJ/SL, JASO MA/MA2 rated - consult manual for exact specifications)
Ethylene glycol based coolant, mix of 50% coolant and 50% distilled water (refer to manual for specific antifreeze concentration)
Brake Fluid Type:
DOT 4 or DOT 5.1 brake fluid (refer to manual for exact specification)
Final Drive Oil Type:
SAE 80W-90 hypoid gear oil (refer to manual for specific viscosity and API rating)
Known Issues
Variator Component Wear:
Variator rollers and ramp plates can wear over time, leading to performance degradation or abnormal noises. Regular inspection and replacement are key.
Fuel Pump Reliability:
Some models may experience issues with the electric fuel pump or its filter, leading to starting problems or poor running.
Charging System:
Stator or voltage regulator failure can lead to battery not charging, causing electrical system issues.
Cooling System Leaks:
Hose connections or radiator can develop leaks, requiring regular inspection and tightening.
📚 Vehicle History
Brand Heritage
Manufacturer:
Aprilia is an Italian manufacturer with a strong heritage in sport motorcycles and performance scooters, known for innovation and design.
Model Evolution
Scarabeo Lineage:
The Scarabeo line has a history dating back to the 1990s, evolving from smaller displacement models to larger, more powerful maxi-scooters like the 500.
Production
Manufacturing Location:
Primarily Italy, though manufacturing might have shifted or involved shared platforms with other Piaggio Group brands.
🏆 Awards & Recognition
Recognitions
Market Reputation:
The Scarabeo 500 was generally well-received for its comfortable ride, strong performance for its class, and distinctive Italian styling, though sometimes criticized for price point compared to Japanese rivals.
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