229 5 SR 50 www.serviceaprilia.
INTRODUCTION SR 50 INTRODUCTION 0 0-1
INTRODUCTION SR 50 TABLE OF CONTENTS 0.1. FOREWORD..................................................................................................................................................... 3 0.1.1. FOREWORD ............................................................................................................................................. 3 0.1.2. REFERENCE MANUALS ..........................................................................................................................
INTRODUCTION SR 50 0.1. FOREWORD 0.1.1. - FOREWORD This manual provides the information required for normal servicing. This manual is intended for use by aprilia Dealers and their qualified mechanics; certain information has been omitted intentionally, as this manual does not purport to provide a comprehensive treatise on mechanics. The persons who will use this manual must be fully conversant with the basics of mechanics and with the basic procedures of motorcycle repair.
INTRODUCTION 0.1.2.
INTRODUCTION SR 50 0.1.3. ABBREVIATIONS/SYMBOLS/CONVENTIONS # < > ≤ ≥ ~ ∞ °C °F ± AC A Ah API AT AV/DC bar DC cc CO CPU DIN DOHC ECU rpm HC ISC ISO kg kgm km km/h kΩ kPa KS kW l LAP LED LEFT SIDE m/s max mbar mi MIN MPH MS MΩ N.A. N.O.M.M. N.O.R.M.
INTRODUCTION TEST T.B.E.I. T.C.E.I. T.E. T.P.
SR 50 GENERAL INFORMATION GENERAL INFORMATION 1 1-1
GENERAL INFORMATION SR 50 TABLE OF CONTENTS 1.1. STRUCTURE OF THE MANUAL...................................................................................................................... 3 1.1.1. CONVENTIONS USED IN THE MANUAL ................................................................................................. 3 1.1.2. SAFETY WARNINGS ................................................................................................................................ 4 1.2. GENERAL RULES.......
GENERAL INFORMATION SR 50 1.1. STRUCTURE OF THE MANUAL 1.1.1. CONVENTIONS USED IN THE MANUAL • This manual is divided in sections and subsections, each covering a set of the most significant components. For quick reference, see the summary of sections. • Unless expressly specified otherwise, assemblies are reassembled by reversing the disassembly procedure. • The terms "left" and "right" are referred to the motorcycle when viewed from the riding position.
GENERAL INFORMATION 1.1.2. SR 50 SAFETY WARNINGS The following precautionary warnings are used throughout this manual in order to convey the following messages: Safety warning. When you find this symbol on the vehicle or in the manual, be careful to the potential risk of personal injury. Disregarding the instructions identified by this symbol may compromise the safety of the user, the motorcycle and third parties. DANGER Indicates a potential hazard which may result in serious injury or even death.
GENERAL INFORMATION SR 50 1.2. 1.2.1. GENERAL RULES BASIC SAFETY RULES CARBON MONOXIDE When an operation must be performed with the engine running, position the motorcycle outdoors in a well-ventilated area. Never run the engine in an enclosed place. Use an exhaust emission extraction system when working indoors. DANGER Exhaust gases contain carbon monoxide, a poisonous gas which, if inhaled, may cause loss of consciousness or even death.
GENERAL INFORMATION SR 50 HYDROGEN GAS AND BATTERY ELECTROLYTE DANGER The battery electrolyte is a toxic, caustic substance containing sulfuric acid and thus able to cause severe burns in case of contact. Wear close-fitting gloves and protective clothing when handling this fluid. If any battery fluid gets on your skin, rinse the affected area with abundant fresh water. Take special care to protect the eyes; even a very small amount of battery fluid can cause blindness.
GENERAL INFORMATION SR 50 REASSEMBLING THE COMPONENTS DANGER Never reuse a circlip or snap ring. These parts must always be replaced once they have been removed. When fitting a new circlip or snap ring, open the ends just enough to allow fitting to the shaft. Make a rule to check that a newly fitted circlip or snap ring is fully housed in its groove. Never use compressed air to clean bearings. CAUTION All bearings must run freely with no hardness or noise.
GENERAL INFORMATION 1.3. 1.3.1. SR 50 DANGEROUS ELEMENTS WARNINGS FUEL DANGER The fuel used to operate engines is highly flammable and becomes explosive under particular conditions. Refueling and maintenance operations should be carried out in a well-ventilated area, with the engine off. Do not smoke when refueling or in the proximity of sources of fuel vapors. Avoid contact with bare flames, sources of sparks or any other source which may ignite the fuel or lead to explosion.
GENERAL INFORMATION SR 50 BRAKE FLUID CAUTION This vehicle is fitted with front and rear disc brakes. Each brake system is operated by an independent hydraulic circuit. The information provided below applies to both brake systems. DANGER Do not drive the vehicle if the brakes are worn or not operating correctly.
GENERAL INFORMATION SR 50 COOLANT DANGER Coolant is toxic when swallowed and is an irritant. Contact with the eyes or skin can cause irritation. In the event of contact with the skin or eyes, rinse repeatedly with abundant water and seek medical attention. If swallowed, induce vomiting, rinse mouth and throat with abundant water and seek medical attention immediately. DO NOT DISPOSE OF IN THE ENVIRONMENT. KEEP AWAY FROM CHILDREN.
GENERAL INFORMATION SR 50 1.4. 1.4.1. RUNNING-IN RUNNING-IN Proper engine running in is essential to preserving engine life and performance over time. Twisty roads and gradients are ideal to break in engine, suspension and brakes effectively. Varying speed frequently is also recommended. This will vary the amount of stress placed on vehicle components continuously, allowing engine parts to cool down when less stressed.
GENERAL INFORMATION 1.5. 1.5.1. VEHICLE IDENTIFICATION POSITION OF THE SERIAL NUMBERS CAUTION Altering the vehicle identification numbers is a legal offence. Altering the frame number invalidates the warranty. FRAME NUMBER The frame number (A) is stamped on the frame central tube. To read it, it is necessary to remove the indicated cover (1). CAUTION The cover (1) can be fitted only in one position. The tabs (2) are on the sides.
GENERAL INFORMATION SR 50 1.6. 1.6.1.
GENERAL INFORMATION 3 4 5 6 1 - 14 SR 50
SR 50 GENERAL INFORMATION 7 8 9 10 1 - 15
GENERAL INFORMATION SR 50 11 12 13 Muffler stamping.
SR 50 GENERAL INFORMATION 15 16 1 - 17
SR 50 PERIODIC MAINTENANCE PERIODIC MAINTENANCE 2 2-1
PERIODIC MAINTENANCE SR 50 TABLE OF CONTENTS 2.1. SPECIFICATIONS ............................................................................................................................................ 3 2.1.1. TECHNICAL DATA.................................................................................................................................... 3 2.1.2. SCHEDULED MAINTENANCE CHART .................................................................................................... 5 2.1.3.
PERIODIC MAINTENANCE SR 50 2.1. 2.1.1. SPECIFICATIONS TECHNICAL DATA DIMENSIONS Max. length (with rear mudguard extension) Max. Width Max.
PERIODIC MAINTENANCE FRAME Type SUSPENSIONS Front Travel Rear Travel BRAKES Front Rear WHEEL RIMS Type Front Rear TIRES Type Front Rear STANDARD INFLATION PRESSURE Front Rear INFLATION PRESSURE (in countries where this is allowed) Front Rear IGNITION Type Type / Spark advance Spark advance / SPARK PLUG Standard Standard Standard As an alternative / Spark plug electrode gap Spark plug electrode gap / ELECTRIC SYSTEM Battery Fuses Fuses Fuses Generator (with permanent magnet) Generator (with permanent magnet
PERIODIC MAINTENANCE SR 50 2.1.2.
PERIODIC MAINTENANCE 2.1.3. SR 50 LUBRICANT TABLE LUBRICANT Gearbox oil PRODUCT RECOMMENDED: 90. F.C., SAE 75W 90 or GEAR SYNTH, SAE 75W - As an alternative to recommended oil, top brand oils meeting or exceeding A.P.I. GL-4 specifications can be used. Mixer oil RECOMMENDED: PROGPX2 or GREEN HIT 2 as an alternative CITY 2T. As an alternative to recommended fluids, top brand oils meeting or exceeding A.P.I. SJ specifications can be used. Front fork fluid RECOMMENDED: F.A. 5W or 5W or FORK 20W. F.
PERIODIC MAINTENANCE SR 50 2.1.4. TIGHTENING TORQUES WARNING The fastening elements listed should be tightened to the specified torque using a torque wrench and applying LOCTITE ® where indicated. Description Q.
PERIODIC MAINTENANCE SR 50 Torque (Nm) Tol. Exhaust Nut M6 Screw M6x16 10 10 ±20% ±20% Screw M8x85 27 ±10% 27 ±10% 3 2 ±20% 25 ±10% 50 10 ±10% ±10% 25 ±10% 50 ±20% 130 ±10% 110 ±10% 27 ±10% 27 ±10% 10 ±20% Description Q.
PERIODIC MAINTENANCE SR 50 Description Q.
PERIODIC MAINTENANCE Description SR 50 Q.ty Type of fastener Torque (Nm) Tol.
PERIODIC MAINTENANCE SR 50 2.1.5. MULTIFUNCTION DIGITAL COMPUTER IE 361 – IE 50 Using the MODE joystick Using the MODE joystick on the RH handlebar, it is possible to choose various functions in sequence; move the MODE joystick to the right or to the left (UP/DOWN) to scroll the functions, select the function by pressing rapidly, confirm data by pressing for a longer period.
PERIODIC MAINTENANCE Chronometer function Quickly press the MODE joystick to start the chronometer. If the MODE joystick is pressed before 10 seconds have elapsed since chronometer start, the current measure is cancelled and a new one is started. If the MODE joystick is pressed after 10 seconds have elapsed since chronometer start, the current measure is stopped, stored and a new one is started. Hold down the MODE joystick for a certain time to stop the measurements.
PERIODIC MAINTENANCE SR 50 • CHRONOMETER sub-menu: this menu allows: DISPLAY: enter this menu to display the times recorded using the Chronometer function. Briefly press the MODE joystick to quit time display mode. DELETE: enter this menu to delete the times recorded using the Chronometer function. All values can be deleted by holding down the MODE joystick for a certain time. • DIAGNOSTICS sub-menu: this menu allows you to perform diagnosis and service operations.
PERIODIC MAINTENANCE ERROR DESCRIPTION SR 50 ECU ERROR CODE Engine overheat ECU 01 Pick-up sensor failure ECU 02 Wrong signal from throttle position sensors ECU 03 Wrong signal from throttle position sensor 1 ECU 04 Wrong signal from throttle position sensor 2 ECU 05 Throttle position sensor 1 malfunction ECU 06 Throttle position sensor 2 malfunction ECU 07 Throttle position sensors malfunction ECU 08 Incorrect charging voltage ECU 09 Oil pump malfunction ECU 10 Air injector malfunct
PERIODIC MAINTENANCE SR 50 DELETE ERRORS: Select this function to delete the errors detected by the ECU and the instrument panel. RESET SERVICE: Select this function to reset the SERVICE warning after the necessary maintenance has been carried out. DISCONNECT: Select this function to cut the instrument panel- ECU connection. WARNING This operation is necessary before connecting to the ECU with AXONE or GAMEBOY, in order to avoid disturbances in data transmission across the ECU and diagnosis instrument.
PERIODIC MAINTENANCE CHANGE KEYS: The instrument panel manages the immobilizer function through encoded keys. In case the keys are lost or the kill switch is changed, it is possible to encode up to 4 keys using this procedure. At the beginning of the procedure you will be prompted to enter the USER CODE. WARNING The user code stored on a new vehicle is 00000. The instrument panel prompts you to insert the first key: WARNING The first key is the one already inserted.
PERIODIC MAINTENANCE SR 50 RESTORE CODE: If the user forgets the USER CODE, it is possible to insert a new code through the Restore Code function. WARNING This procedure irreversibly previous User Code. deletes the KM/MILES: use this function to select the unit of measurement for the Tachometer / Odometer. ESC: Select this item to quit the diagnosis environment. • LANGUAGE FUNCTION sub-menu: choose the desired language from this menu.
PERIODIC MAINTENANCE 2.1.6. MULTIFUNCTION DIGITAL COMPUTER C 364 Multifunction indicator functions Use the Mode button (2), on the LH handlebar, to select among various functions: clock setting, odometer (ODO), trip meter (TRIP), battery voltage value and trip meter reset. Odometer (ODO). When the instrument panel is switched on, the multifunction display (1) shows the odometer function (ODO). TRIP. With the odometer display (ODO), press the Mode button (2) once to display the function (TRIP).
PERIODIC MAINTENANCE SR 50 2.2. SCHEDULED MAINTENANCE 2.2.1. BRAKE SYSTEM WARNING In case of excessive stroke of the brake lever, excessive elasticity or air bubbles, bleed the air out of the circuit. Do not use or mix different types of silicone or oil fluids. Prevent water or dust from accidentally getting into the circuit. CAUTION The following procedure refers to both brake systems. Check CAUTION Place the vehicle on a firm and level surface. • • Position the vehicle on the center stand.
PERIODIC MAINTENANCE WARNING Avoid prolonged exposure of brake fluid to air. Brake fluid is hygroscopic and will absorb moisture from the air. Keep the brake fluid reservoir open JUST LONG ENOUGH to top up the level. • • Raise and remove the cover (1). Remove the gasket (2). CAUTION In order not to spill the brake fluid while topping up, do not shake the vehicle. • Top up the tank (3) with brake fluid to the correct level.
SR 50 PERIODIC MAINTENANCE CHECKING BRAKE PAD WEAR CAUTION The following instructions apply to both brakes. Outlined below is a quick brake pad inspection procedure: • Position the vehicle on the center stand. • Using a lamp and a mirror placed between the brake caliper and pads, visually check as follows. FRONT BRAKE CALIPER - From below, on the front part, for the left pad; From above, on the front part, for the right pad; look through the rim.
PERIODIC MAINTENANCE BLEEDING THE BRAKING SYSTEM Any air present inside the hydraulic circuit will serve as a "pad" by absorbing most of the pressure coming from the brake master cylinder, thus reducing caliper efficiency during braking. If air is present inside the circuit, the brake control is "spongy" and braking efficiency is reduced.
PERIODIC MAINTENANCE SR 50 2.2.2. • • • CLEANING THE AIR FILTER Remove the air filter, see (REMOVING THE AIR FILTER). Wash the filtering element with clean, non-flammable solvents or solvents with a high volatility point, then let it dry thoroughly. Apply a filter oil on the entire surface of the filtering element. WARNING The partial cleaning of the filter does not exclude or postpone the replacement of the filter itself. Do not start the engine when the air filter is not in place.
PERIODIC MAINTENANCE 2.2.3. SR 50 COOLANT CHECKING AND COOLANT LEVEL TOPPING UP THE WARNING Wait for the engine to cool down before checking or topping up the coolant level. • Stop the engine and wait until it has cooled down. CAUTION Place the vehicle on a firm and level surface. • • Remove the front cover, see (REMOVING THE FRONT COVER). Make sure that the level of the fluid contained in the expansion reservoir is included between the "MIN" and "MAX" marks. MIN = minimum level.
SR 50 • • PERIODIC MAINTENANCE Start the vehicle and let it warm up. Bleed again and top up.
PERIODIC MAINTENANCE 2.2.4. GEAR FLUID IE361 – C364 CAUTION Use only recommended oil, see (LUBRICANT CHART). • Ride several kilometers (miles) to warm up the engine to operating temperature and then stop the engine. Check • • Position the vehicle on firm and level ground. Position the vehicle on the center stand. WARNING Allow several minutes for the engine and exhaust system to cool down. • • • • Unscrew and extract the plug/dipstick. Clean the part in contact with the oil with a clean cloth.
PERIODIC MAINTENANCE SR 50 CHANGE • • Position the vehicle on firm and level ground. Position the vehicle on the center stand. WARNING Allow several minutes for the engine and exhaust system to cool down. • • • • • Stop the engine and let it cool down, in order to allow the oil to flow into the crankcase and cool down. Unscrew and extract the plug/dipstick. Take a receptacle of suitable capacity and set it under the drain screw. Release and remove the drain screw.
PERIODIC MAINTENANCE 2.2.5. GEAR FLUID IE50 CAUTION Use only recommended oil, see (LUBRICANT CHART). CHECK • Ride several miles to warm up the engine to operating temperature and then stop the engine. • Position the vehicle on firm and level ground. • Position the vehicle on the center stand. WARNING Allow several minutes for the engine and exhaust system to cool down. • Place a graduated receptacle (1) with at least 150 cm3 capacity (9.15 in3) under the drain plug (2).
PERIODIC MAINTENANCE SR 50 • • • • Unscrew and remove the filler plug (3) and oil drain plug (2). Let the oil fully drain off the crankcase. Tighten the drain plug (2) and pour through the filler 130 cm3 (7.93 in3) of oil, see (LUBRICANT CHART). Tighten the filler plug (3). WARNING Firmly tighten the filler and drain plugs and ensure there are no oil leaks. Periodically check that there are no leaks at the crankcase cover gasket.
PERIODIC MAINTENANCE 2.2.6. MIXER OIL IE361 – C364 TOPPING UP CAUTION The vehicle fits a separate mixer that mixes fuel and oil, necessary for lubrication. • • • • Remove the front cover, see (REMOVING THE FRONT COVER). Remove the plug. Fill with oil, see (LUBRICANT CHART). Refit the plug. AIR BLEED WARNING If the oil in the mixer oil reservoir is low or if the mixer oil line - from the mixer to the reed assembly - is removed, it is necessary to bleed the system.
PERIODIC MAINTENANCE SR 50 2.2.7. MIXER OIL IE50 TOPPING UP CAUTION The vehicle fits a control unit that manages an electronic pump controlling the correct quantity of oil for engine lubrication. • • • • Remove the front cover, see (REMOVING THE FRONT COVER). Remove the plug. Fill with oil, see (LUBRICANT CHART) Refit the plug. AIR BLEED CAUTION The vehicle fits a self-bleeding electronic pump.
FUEL SYSTEM SR 50 FUEL SYSTEM 3 3-1
FUEL SYSTEM SR 50 TABLE OF CONTENTS 3.1. FUEL TANK ...................................................................................................................................................... 3 3.1.1. FUEL FEED SYSTEM DIAGRAM IE361 – IE50 ........................................................................................ 3 3.1.2. FUEL SUPPLY SYSTEM DIAGRAM C364................................................................................................ 4 3.1.3.
FUEL SYSTEM SR 50 3.1. FUEL TANK 3.1.1. FUEL FEED SYSTEM DIAGRAM IE361 – IE50 Key: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Fuel tank; Fuel level sensor; Fuel collection rubber element; Three-way fitting; Fuel filter; Fuel pump; Fuel tank-filter line; Fuel filter-pump line; “Overflow” line; Fuel return hose; Breather hose; High-pressure fuel from injection unit; Low-pressure fuel from injection unit.
FUEL SYSTEM 3.1.2. FUEL SUPPLY SYSTEM DIAGRAM C364 Key: 1. 2. 3. 4. 5. 6. 7. 8. Fuel tank; Fuel level sensor; Fuel collection rubber element; “Overflow” line; Breather hose; Vacuum fuel cock; Fuel hose; Vacuum hose.
FUEL SYSTEM SR 50 3.1.3. • REMOVING THE FUEL TANK IE361 – IE50 • Remove the tool kit compartment, see (REMOVING THE TOOL KIT COMPARTMENT). Remove the tail guard, see (REMOVING THE TAIL GUARD). Disconnect the fuel sensor connector. • Loosen and remove the two screws. • Disconnect the fuel pump connector. • Move the tank aside to remove the breather line from the frame. Disconnect the two quick-release fittings on the injection unit.
FUEL SYSTEM • • • 3-6 Loosen and remove the two screws, collect the spacers. Release the seat release cable on the tank end. Remove the fuel tank together with helmet compartment.
FUEL SYSTEM SR 50 3.1.4. • REMOVING THE FUEL TANK C364 • Remove the tool kit compartment, see (REMOVING THE TOOL KIT COMPARTMENT). Remove the tail guard, see (REMOVING THE TAIL GUARD). Disconnect the fuel sensor connector. • Loosen and remove the two screws. • Disconnect breather pipe from frame end. • CAUTION Place some paper under the coupling to collect any fuel spillage. • • Disconnect the fuel delivery lines (1) and vacuum lines (2). Fold the delivery line (1) on itself and tie.
FUEL SYSTEM • • • 3-8 Loosen and remove the two screws. Release the seat release cable on the tank end. Remove the fuel tank together with helmet compartment.
FUEL SYSTEM SR 50 3.1.5. REMOVING THE FUEL SENSOR • • • Raise the seat. Remove cover. Disconnect the connector. • Release the sensor and hook it with a suitable tool, turn it counterclockwise. • Remove the fuel sensor.
FUEL SYSTEM 3.2. AIR FILTER 3.2.1. REMOVING THE AIR FILTER AND THE AIR BOX IE361 - IE50 REMOVING THE AIR FILTER IE 361 - IE 50 • Loosen and remove the three screws. • Loosen and remove the two screws, collect the washers and the spacers. • Move the cover aside, do not disconnect the air intake line.
SR 50 • FUEL SYSTEM Remove the air filter. REMOVING THE AIR BOX IE 361 - IE 50 • Loosen and remove the two screws, collect the washers and the spacers. • • Loosen and remove the rear mudguard screw. Disconnect the air intake line. • Loosen the clamp and remove the throttle body intake hose. Remove the air box.
FUEL SYSTEM 3.2.2. REMOVING THE AIR FILTER AND THE AIR BOX C364 REMOVING THE AIR FILTER C364 • • Loosen and remove the three screws (1). Loosen and remove the two screws (2), collect the washers. WARNING Do not force during removal. The air box cover (3) stays connected to the line (4). • • • Partially remove the air box cover (3). Remove the mesh (5). Remove the filter (6). REMOVING THE AIR BOX C364 • Loosen and remove the two screws (2), collect the washers. • • • Loosen the tie (7).
FUEL SYSTEM SR 50 3.3. 3.3.1. INJECTION UNIT INJECTION SYSTEM DIAGRAM IE50 Key: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
FUEL SYSTEM 3.3.2. REMOVING THE THROTTLE BODY IE361 – IE50 • Loosen the clamp and remove the throttle body intake manifold from the air box end. • Disconnect the connector. • Loosen the clamp. • Remove the throttle body from the right side of the vehicle, keep it attached to the throttle cable. CAUTION If the throttle body is to be completely removed, disconnect it from the throttle cable.
FUEL SYSTEM SR 50 3.3.3. • REMOVING THE INJECTION UNIT IE361 – IE50 • Move the fuel tank aside, keep it connected to the seat release cable and to fuel pump wiring, see (REMOVING THE FUEL TANK). Disconnect the fuel injector connector. • Disconnect the compressed air inlet line. • • Loosen and remove the two screws. Remove the injection unit.
FUEL SYSTEM 3.4. 3.4.1. Key: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23.
FUEL SYSTEM SR 50 3.4.2. REMOVING THE CARBURETOR C 364 • Loosen and remove the two screws. • Loosen and remove the screw. • Loosen the carburetor clamp. • Remove the air box.
FUEL SYSTEM • Disconnect the automatic choke connector. • • Pinch the two heater hoses. Remove the two clamps and remove the hoses. • • Pinch the fuel hose. Remove the tie and disconnect the fuel hose. • • Pinch the oil hose. Remove the tie and disconnect the oil hose.
SR 50 • Remove the tie and disconnect the vacuum hose. • Loosen the tie and remove the carburetor from the intake manifold. • Loosen and remove the screw and remove the throttle cable with gate.
ENGINE SR 50 ENGINE 4 4- 1
ENGINE SR 50 TABLE OF CONTENTS 4.1. ENGINE IE 361................................................................................................................................................. 3 4.1.1. REMOVING THE ENGINE IE 361 ............................................................................................................. 3 4.1.2. INSTALLING THE ENGINE IE 361............................................................................................................ 8 4.2. ENGINE IE 50....
ENGINE SR 50 4.1. 4.1.1. • ENGINE IE 361 REMOVING THE ENGINE IE 361 • • To remove the crankcase, first remove the lower shield, the battery, the fuel tank, the throttle body, keep it connected to the throttle cable and drain the cooling system. Using a belt and an A-frame, lift the vehicle rear end. Loosen and remove the shock absorber upper screw. • Loosen and remove the two cable guide screws. • • Loosen and remove the two screws.
ENGINE • Slide the two intake hoses out of the ties on the frame. CAUTION Place some paper under the coupling to collect any oil spillage. • • Disconnect the two mixer oil hoses Fold the lines and tie them. • Remove the cooling system hose from the head. • Disconnect the spark plug cap.
SR 50 • Remove the rubber plug. • Open the tab and remove the mixer oil pump control cable. • Disconnect the fuel injector connector. • Disconnect the engine temperature sensor connector.
ENGINE • Disconnect the compressed air injector connector. • Loosen the screw and remove the two ground cables. • Disconnect the starter motor positive cable from the relay end. • Remove the clamp.
SR 50 • Working on the right side, loosen and remove the nut. • • Working on the left side, remove the pin. Remove the engine.
ENGINE 4.1.2. • INSTALLING THE ENGINE IE 361 • Move the frame in small motions until the holes match perfectly. Working on the left side, fit the pin. • Working on the right side, tighten the nut. • Connect the starter motor positive cable to the relay. • Position the two ground cables and tighten the screw.
SR 50 • Connect the connector to the compressed air injector. • Connect the engine temperature sensor connector. • Connect the connector to the fuel injector. • Fasten the wiring with a new tie.
ENGINE • Reposition the mixer oil pump cable in its housing and close the tab. CAUTION it might be necessary to adjust the mixer oil pump by making the two marks match. • Fit the spark plug cap. • • Position the cooling system hose onto the head. Tighten the clamp.
ENGINE SR 50 • Connect the generator connector. • • • Fit the cooling system hose to the coolant pump. Fasten the hose with the tie. Fill and bleed air off the cooling system. • Connect the two mixer oil hoses WARNING Before using the vehicle, bleed the mixer oil pump, see (MIXER OIL IE361 - C364) and (MIXER OIL IE50). • Place the two intake hoses on the frame.
ENGINE • • Fit the rear brake caliper in place. Tighten the two screws. • Reposition the two cable guides of the rear brake fluid hose. Tighten the two screws. • • • Tighten the shock absorber top screw. Fit the throttle body, the fuel tank, the battery, the lower shield.
ENGINE SR 50 4.2. 4.2.1. • ENGINE IE 50 REMOVING THE ENGINE IE 50 • • To remove the crankcase, first remove the lower shield, the battery, the fuel tank, the throttle body, keep it connected to the throttle cable and drain the cooling system. Using a belt and an A-frame, lift the vehicle rear end. Loosen and remove the shock absorber upper screw. • Loosen and remove the two cable guide screws. • • Loosen and remove the two screws.
ENGINE • Slide the two intake hoses out of the ties on the frame. CAUTION Place some paper under the coupling to collect any oil spillage. • • Disconnect the mixer oil hose Fold the lines and tie them. • Remove the cooling system hose from the head. • Disconnect the spark plug cap.
SR 50 • Disconnect the fuel injector connector. • Disconnect the engine temperature sensor connector. • Disconnect the compressed air injector connector. • Working on the left side, loosen the screw and remove the ground cable.
ENGINE • Disconnect the starter motor positive cable connector and remove the tie. • Disconnect the two wires. • Working on the left side, loosen and remove the nut. • • Working on the right side, remove the pin. Remove the engine.
ENGINE SR 50 4.2.2. • INSTALLING THE ENGINE IE 50 • Move the frame in small motions until the holes match perfectly. Working on the right side, fit the pin. • Working on the left side, tighten the nut. • Connect the two wires. • Connect the starter motor positive cable connector and place a new tie on the wiring.
ENGINE • Position the ground cable and tighten the screw. • Connect the connector to the compressed air injector. • Connect the engine temperature sensor connector. • Connect the connector to the fuel injector.
SR 50 • Fit the spark plug cap. • • Position the cooling system hose onto the head. Tighten the clamp. • Connect the mixer oil hose • Place the two intake hoses on the frame.
ENGINE • • Fit the rear brake caliper in place. Tighten the two screws. • Reposition the two cable guides of the rear brake fluid hose. Tighten the two screws. • • • Tighten the shock absorber top screw. Fit the throttle body, the fuel tank, the battery, the lower shield.
ENGINE SR 50 4.3. 4.3.1. • • • ENGINE C 364 REMOVING THE ENGINE C 364 Remove the air box hose. Remove the brake caliper, see (REMOVING THE BRAKE CALIPER). Loosen and remove the fifteen screws and remove the converter cover. • Release the mixer oil pump drive cable. • • Pinch the oil hose delivery. Remove the tie and the hose.
ENGINE • • • • Remove the carburetor, see (REMOVING CARBURETOR). Remove the spark plug cap. Disconnect the temperature sensor connector. SR 50 THE • Remove the two rear side panels, see (REMOVING THE REAR SIDE PANELS). Remove the exhaust, see (REMOVING THE EXHAUST). Disconnect the alternator connector. • Loosen and remove the four screws. • Remove the tie and the cover.
SR 50 • Loosen and remove the two upper screws securing the lower cover. • • Loosen and remove the lower screw of the lower cover. Slide down the lower protection. • Loosen and remove the screw and remove the starter motor ground cables • Remove the clamp.
ENGINE • Disconnect the connector. • Loosen and remove the drain screw of the cooling system and drain it. • Loosen the clamp and remove the hose on the thermostatic valve end. • Using a belt and a suitable tool, lift the vehicle rear end. Remove the rear shock absorber lower screw, see (REMOVING THE REAR SHOCK ABSORBER). Working on the right side, loosen and remove the nut.
SR 50 • • ENGINE Working on the opposite side, remove the pin. Remove the engine.
ENGINE 4.3.2. • INSTALLING THE ENGINE C 364 • Move the frame in small motions until the holes match perfectly. Insert the pin. • Working on the right side, fit and tighten the nut. • • Fit the hose in the thermostatic valve. Fit a new clamp and tighten. • • Fit and tighten the drain screw. Fill the cooling system.
SR 50 • Connect the connector. • Fit a new clamp to the wiring. • • Position the starter motor ground cables. Fit and tighten the screw. • • Fit the lower protection. Fit and tighten the lower screw of the lower cover.
ENGINE • Fit and tighten the two upper screws securing the lower cover. • • Fit cover. Fit and tighten a new clamp. • Fit and tighten the four screws. • Connect the alternator connector.
SR 50 • • • • • Connect the temperature sensor. Fit the spark plug cap. Install the exhaust. Install the two rear side panels. Install the carburetor. • • • Fit the hose to the mixer oil pump. Fit the clamp. Pinch the oil hose delivery. • Fit the mixer oil pump drive cable. • • • • Fit the converter cover. Fit and tighten the fifteen screws. Fit the rear brake caliper. Fit the air box hose.
ENGINE 4.4. SECONDARY AIR SYSTEM 4.4.1. SECONDARY AIR SYSTEM SYSTEM DIAGRAM Key: 1. 2. 3. 4. 4 - 30 Intake manifold; Secondary air valve; From the engine; Exhaust.
SR 50 ENGINE SAS The Secondary Air System (SAS) has been developed to reduce carbon oxide and unburnt hydrocarbon emissions in vehicles that are not equipped with a lambda sensor. Natural air (which is rich in oxygen) is channelled into the exhaust stream to trigger a post-combustion process that raises the temperature of the exhaust gasses for a quick light-off of the catalyst.
ENGINE REMOVING AND CLEANING THE AIR FILTER • Loosen the two screws and remove the aluminum cover of the system. • Remove the plastic cover and the filter. • Remove the single-acting valve housing, check the valve condition and refit them in their housings. Wash and blow the filter with compressed air.
SR 50 ENGINE 4- 33
CYCLE PARTS SR 50 CYCLE PARTS 5 5-1
CYCLE PARTS SR 50 TABLE OF CONTENTS 5.1. OUTER STRUCTURES.................................................................................................................................... 3 5.1.1. REMOVING THE SEAT............................................................................................................................. 3 5.1.2. REMOVING THE PASSENGER GRAB HANDLE ..................................................................................... 4 5.1.3. REMOVING THE TAIL GUARD......
CYCLE PARTS SR 50 5.1. 5.1.1. OUTER STRUCTURES REMOVING THE SEAT • Remove the central inspection cover. • Slide out the split pin. • • • Raise the seat. Remove pin. Remove the seat.
CYCLE PARTS 5.1.2. • • • 5-4 REMOVING THE PASSENGER GRAB HANDLE Raise the seat. Loosen and remove the four screws. Remove the passenger grab handle.
CYCLE PARTS SR 50 5.1.3. • • REMOVING THE TAIL GUARD Remove the passenger grab handle, see (REMOVING THE PASSENGER GRAB HANDLE). Working on either side, loosen and remove the two side screws. • Loosen and remove the fourteen top screws. • Loosen and remove the four rear screws. • Loosen and remove the two lower screws.
CYCLE PARTS • • 5-6 Disconnect the tail light connector. Remove the tail guard together with the license plate holder.
CYCLE PARTS SR 50 5.1.4. REMOVING THE LOWER SHIELD • Loosen and remove the three front screws. • Working on either side, loosen and remove the rear screw. • Loosen and remove the three top screws. • Remove the lower shield.
CYCLE PARTS 5.1.5. REMOVING THE FRONT COVER • Loosen and remove the two outer screws. • • Lift the front cover just enough to release it. Remove the front cover. CAUTION To easily remove the cover, raise it from the right first, then from the left.
CYCLE PARTS SR 50 5.1.6. REMOVING THE FRONT MUDGUARD • Working on the right side, loosen and remove the odometer cord cable guide screw. • Loosen and remove the mudguard front right screw. • Working on the left side, loosen and remove the brake line cable guide screw. • • Loosen and remove the mudguard front left screw. Remove the front mudguard.
CYCLE PARTS 5.1.7. REMOVING THE REAR MUDGUARD • • Remove the air box, see (REMOVING THE AIR BOX). Working on the left side, loosen and remove the screw. • Working on the right side, loosen and remove the screw, collect the washer and the spacer. Remove the rear mudguard.
CYCLE PARTS SR 50 5.1.8. REMOVING THE TOOL KIT COMPARTMENT • Lift and remove the tool kit compartment cover. • • Loosen and remove the screw. Remove the tool kit compartment.
CYCLE PARTS 5.1.9. • REMOVING THE INNER SHIELD • Remove the front cover, see (REMOVING THE FRONT COVER). Loosen and remove the two screws. • Loosen and remove the ten screws. • • Loosen and remove the two screws of the bag hook. Remove the bag hook. • Loosen and remove the screw below the bag hook.
CYCLE PARTS SR 50 • Remove the rubber switch/steering lock. • • Slightly raise the inner shield and slide it out of its tabs. Loosen and remove the two screws securing the seat lock. Remove the inner shield.
CYCLE PARTS 5.1.10. • REMOVING THE HEADLIGHT • Remove the front cover, see (REMOVING THE FRONT COVER). Loosen and remove the two screws. • Loosen and remove the eight screws. • Working on either side, loosen and remove the three inner screws. • Loosen and remove the central screw.
SR 50 • • Move the headlight with the two side fairings forward. Disconnect the two headlight connectors. • Remove the headlight with the two side fairings.
CYCLE PARTS 5.1.11. • REMOVING THE FRONT WHEELHOUSE • Remove the headlight, see (REMOVING THE HEADLIGHT). Remove the front wheel, see (REMOVING THE FRONT WHEEL). Remove the front mudguard, see (REMOVING THE FRONT MUDGUARD). Loosen and remove the two front screws. • Release the tie and the two cooling system hoses. • Loosen and remove the two inner screws. • Release the two wheelhouse shells and slide them out of the fork.
CYCLE PARTS SR 50 5.1.12. REMOVING THE INSTRUMENT PANEL • • Loosen and remove the four front screws. Remove the headlight fairing. • Loosen and remove the three top screws. • • Loosen and remove the two lower screws. Release the handlebar fairing, move it down and keep it connected to the turn indicator wirings. • Disconnect the instrument panel connector. WARNING During reassembly, ensure to perfectly align the connector with the instrument panel, to avoid damaging the instrument panel pins.
CYCLE PARTS • Loosen and remove the three screws of the instrument panel subframe. • Remove the instrument panel.
CYCLE PARTS SR 50 5.2. 5.2.1. • • • • EXHAUST SYSTEM REMOVING THE EXHAUST SYSTEM IE361 – C364 Remove the lower shield, see (REMOVING THE LOWER SHIELD). Loosen and remove the two studs on the stud bolts. Working on the right side, loosen and remove the two screws, collect the washers and the spacers. Remove the exhaust system.
CYCLE PARTS 5.2.2. REMOVING THE EXHAUST SYSTEM IE50 • • Loosen and remove the screw (1). Loosen and remove the screw (2). • Loosen and remove the screw (3) securing the silencer to the engine. Loosen and remove the screw (4) securing the mudguard to the engine. Raise the mudguard. Loosen and remove the screw (5) securing the silencer to the engine. Remove the silencer.
CYCLE PARTS SR 50 5.3. 5.3.1. FRONT WHEEL FRONT WHEEL DIAGRAM Key: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Front wheel rim; Bearing; Inner spacer; Left spacer; Wheel shaft; Tubeless valve; Brake disc; Brake disc screws; Tire; Drive; Drive seal; Odometer drive fitting; Washer; Nut.
CYCLE PARTS 5.3.2. REMOVING THE FRONT WHEEL WARNING When removing/refitting, pay utmost attention not to damage the brake line, disc and pads. • • • • Position the vehicle on the center stand. Set a support under the frame. Remove the brake caliper, see (CHANGING THE FRONT AND REAR BRAKE PADS). Loosen and remove the wheel shaft nut. • • • • Loosen the shaft screws. Loosen and remove the wheel shaft. Collect the odometer drive fitting. Slide out the wheel.
CYCLE PARTS SR 50 5.4. 5.4.1. REAR WHEEL REAR WHEEL DIAGRAM Key: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.
CYCLE PARTS 5.4.2. • • • • • REMOVING THE REAR WHEEL Position the vehicle on the center stand. Set a support under the frame. Remove the exhaust system, see (REMOVING THE EXHAUST SILENCER). Loosen and remove the two screws. Slide out the rear brake caliper, keep it connected to the fluid line. • Remove the cover. • • • • Remove the split pin on the wheel shaft. Remove the nut cover. Loosen and remove the wheel shaft nut. Remove the rear wheel together with brake disc, slide it out from the right side.
CYCLE PARTS SR 50 5.5. 5.5.1. • • BRAKING SYSTEM CHANGING THE BRAKE PADS Position the vehicle on the center stand. Remove the brake caliper from the disc, but leave the line connected. For the front brake caliper only: • Remove the brake caliper cover. WARNING Be careful not to damage the rim paint during removal and reassembly of the caliper on the disc. While changing pads, protect the rim with tape.
CYCLE PARTS • • • • Remove the snap ring (1). Remove the pin (2). Remove the spring (3). Remove the pads (4) sliding them out one at a time. WARNING Do not operate the brake lever when the pads are not in place or the caliper piston might come off its housing, thus causing brake fluid leakage. Always change both pads and ensure they are correctly in place inside the caliper. • Fit two new brake pads (4). • • • Correctly seat the spring (3). Fit the pin (2). Fit the snap ring (1).
CYCLE PARTS SR 50 5.6. 5.6.1. STEERING STEERING DIAGRAM Key: 1. 2. 3. 4. 5. 6.
CYCLE PARTS 5.7. 5.7.1. FRONT FORK FRONT FORK DIAGRAM Key: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21.
CYCLE PARTS SR 50 5.7.2. • • • • REMOVING THE FORK LEG Remove the headlight, see (REMOVING THE HEADLIGHT). Remove the front wheel, see (REMOVING THE FRONT WHEEL). Remove the front mudguard, see (REMOVING THE FRONT MUDGUARD). Loosen and remove the two inner screws. • Release the wheelhouse cover and slide it out of the fork. • Completely turn the handlebar to the side of the fork leg to be removed. Loosen the plate clamp screw.
CYCLE PARTS 5.7.3. • DISASSEMBLING THE STANCHION Remove the stanchion assembly, see (REMOVING THE FORK LEG). CAUTION Prepare a graduated receptacle with a capacity of at least 300 cm3 (18.31 in3.). • Let the fork leg enter the stanchion completely, turn the stanchion assembly and let the fluid drain in the container. WARNING Check the oil level. If lower than 103 cm3 (6.28 3 in ), top up or change. • • • • • Loosen and remove the screw (1) (bottom end) and collect the copper washer (2).
CYCLE PARTS SR 50 5.8. 5.8.1. • REAR SUSPENSION REMOVING THE SHOCK ABSORBER Position the vehicle on the center stand. WARNING Fit a suitable shim in-between the frame and the rear wheel to avoid the air box sinking and pushing on the inspection cover. • Loosen and remove the top screw. • • Loosen and remove the nut and remove the screw. Remove the rear shock absorber.
COOLING SYSTEM SR 50 COOLING SYSTEM 6 6-1
COOLING SYSTEM SR 50 TABLE OF CONTENTS 6.1. COOLING SYSTEM.......................................................................................................................................... 3 6.1.1. DIAGRAM .................................................................................................................................................. 3 6.2. EMPTYING THE COOLING SYSTEM.............................................................................................................. 4 6.
COOLING SYSTEM SR 50 6.1. 6.1.1. COOLING SYSTEM DIAGRAM Key: 1) 2) 3) 4) 5) 6) 7) 8) Expansion reservoir with plug; Radiator; Expansion reservoir-radiator hose; Breather hose; Radiator-pump hose; Head-radiator hose; To water pump; From head.
COOLING SYSTEM 6.2. 6.2.1. EMPTYING THE COOLING SYSTEM EMPTYING THE COOLING SYSTEM CAUTION Before proceeding with emptying the cooling system, it is necessary to take a receptacle with a suitable capacity. • • • • • • Remove the front cover, see (REMOVING THE FRONT COVER). Unscrew and remove the expansion reservoir plug. Remove the lower shield, see (REMOVING THE LOWER SHIELD). Disconnect the generator connector. Place the container under the coolant pump.
ELECTRICAL SYSTEM SR 50 ELECTRICAL SYSTEM 7 7-1
ELECTRICAL SYSTEM SR 50 TABLE OF CONTENTS 7.1. CHECKING THE ELECTRICAL COMPONENTS ............................................................................................. 3 7.1.1. CHECKING THE COMPONENTS IE361................................................................................................... 3 7.1.2. CHECKING THE COMPONENTS IE50..................................................................................................... 7 7.1.3. CHECKING THE COMPONENTS C364....................
ELECTRICAL SYSTEM SR 50 7.1. 7.1.1.
ELECTRICAL SYSTEM 3 Starter motor current absorbed in operation: 20 A 4 Fuel pump: absorption: 0.35 A 5 Tail light: parking/stop light : 12 V – 5 / 21 W 6 Ignition coil: primary resistance: 0.
ELECTRICAL SYSTEM SR 50 7 Fuel sensor: resistance across terminals 1 and 3: 5 ohms with full fuel tank 38 ohms with half full fuel tank 100 ohms with empty fuel tank 8 Fuses: 10A fuse (1) - From ignition switch to: • Lights • Low-High beam relay • Horn • Diagnostics circuit 15A fuse (2) - From battery to: • Rectification/charge circuit • Ignition switch • Positive permanent on instrument panel • Injection relay • Engine kill switch • Instrument panel key-operated power Stoplights Mixer oil reserve sensor
ELECTRICAL SYSTEM 11 Throttle body FUEL INJECTOR winding resistance: 1.7 ohms THROTTLE POSITION SENSOR (TPS): resistance across terminals 1 and 4: 1.1 kOhms Throttle grip CLOSED resistance across terminals 1 and 2: 1.1 kOhms resistance across terminals 1 and 3: 1.9 kOhms Throttle grip OPEN resistance across terminals 1 and 2: 1.9 kOhms resistance across terminals 1 and 3: 1.1 kOhms tolerance on measured values: ± 10% 12 Air injector: winding resistance: 1.
ELECTRICAL SYSTEM SR 50 7.1.2.
ELECTRICAL SYSTEM 3 Starter motor current absorbed in operation: 20 A 4 Fuel pump: absorption: 0.35 A 5 Tail lights: parking/stop light 12 V – 5 / 21 W 6 Ignition coil: primary resistance: 0.
ELECTRICAL SYSTEM SR 50 7 Fuel sensor: resistance across terminals 1 and 3: 5 ohms with full fuel tank 38 ohms with half full fuel tank 100 ohms with empty fuel tank 8 Fuses: 10A fuse (1 - 2) - From ignition switch to: • • • • • • Horn Rectification/charge circuit Stoplights Injection relay Engine kill switch Instrument panel key-operated power Turn indicators Mixer oil reserve sensor Fuel sensor Coolant temperature sensor 9 Charging voltage: voltage 13.5 V ± 0.
ELECTRICAL SYSTEM 11 Throttle body FUEL INJECTOR winding resistance: 1.7 ohms THROTTLE POSITION SENSOR (TPS): resistance across terminals 1 and 4: 1.1 kOhms Throttle grip CLOSED resistance across terminals 1 and 2: 1.1 kOhms resistance across terminals 1 and 3: 1.9 kOhms Throttle grip OPEN resistance across terminals 1 and 2: 1.9 kOhms resistance across terminals 1 and 3: 1.1 kOhms tolerance on measured values: ± 10% 12 Air injector: winding resistance: 1.
ELECTRICAL SYSTEM SR 50 7.1.3. CHECKING THE COMPONENTS C364 1 Generator: two-phase generator winding resistance: 0.
ELECTRICAL SYSTEM 3 Starter motor absorption in operation: 20 A. 4 Tail lights: parking/stop light 12 V – 5 / 21 W 5 Fuel sensor: resistance (measure across pin 1 and 2) 5 ohms with full fuel tank 38 ohms with half full fuel tank 100 ohms with empty fuel tank 6 Fuses: 7.
ELECTRICAL SYSTEM SR 50 7 Headlight: low beam high beam 12 V – 35 W 12 V – 35 W 8 Engine temperature sensor: NTC sensor resistance: 560 ohms (at 25°C) resistance: 40 ohms (at 100°C) 7 - 13
ELECTRICAL SYSTEM 7.2. 7.2.1.
ELECTRICAL SYSTEM SR 50 Key: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49.
ELECTRICAL SYSTEM 7.2.2.
ELECTRICAL SYSTEM SR 50 Key: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49.
ELECTRICAL SYSTEM 7.2.3.
ELECTRICAL SYSTEM SR 50 Key: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38.
aprilia s.p.a. via G.Galilei, 1 30033 Noale (VE) Italy tel. +39 041.5829111 fax +39 041.5829190 www.aprilia.com www.serviceaprilia.
