aprilia QUICK WORKSHOP HANDBOOK Electronic air injection Aprilia Ditech Engine 1095 2
Air-injection 50 cc CONTENTS INTRODUCTION General safety norms 1 Technical data 2 Oil chart 3 Special engine tools 4 Injection troubleshooting 5 Disassembly/Reassembly sequence 6 Produced by Training and Documentation Department aprilia s.p.a. Via G. Galilei, 15 - 30033 Noale (VE) - Italy Tel. +39 - 041 55829111 Fax + 39 - 041 441054 www.aprilia.com Produced and printed by Studio Gallo Design srl Via Mogno,34/1 35012 Camposampiero (PD) tel. 049 - 9303475 fax. 049 - 9317954 Italy www.stgallo.
Air-injection 50 cc GENERAL SAFETY NORMS WASTE TRANSMISSION OIL CARBON MONOXIDE DANGER If the engine must be switched on to carry out certain operations make sure the room is well ventilated or open to the outside. Never switch on the engine in a closed room, unless there is a smoke and fume removal system installed and the operating. Use latex gloves for maintenance operations involving contact with oil. If left in contact with the skin for long periods, used engine oil can cause skin cancer.
Air-injection 50 cc BEFORE DISASSEMBLY - Remove dirt, mud, dust and foreign bodies from the vehicle before disassembling the components. - Use all the tools specifically designed for the vehicle. DISASSEMBLY - Before separating pipes or wires etc. (joints and junctions) mark each part with a unique marking. Each piece should be clearly marked for reassembly purposes. -Clean and wash the disassembled components with close to non-inflammable detergent.
Air-injection 50 cc TECHNICAL DATA ENGINE Type Engine type Number of valves Number of cylinders Piston displacement Bore/Stroke Corrected compression ratio Idle rpm Starter system Clutch Gearbox Lubrication system Cooling system air/injection air-injection with direct petrol injection mono-cylindrical horizontal 49.38 cm3 41.0 mm / 37.4 mm rc = 10.7 ± 0.
Air-injection 50 cc TIGHTENING TORQUE 50 cc AIR INJECTION ENGINE Application Pick-up locking Stator locking Transmission steel plate locking Throttle body (with roller) hose clamp locking Suction manifold (built-in, hexagonal) locking Screws and pin securing intake manifold Transmission cover Variator cover Bendix support locking Starter motor L/r carter locking Wheel bearing retaining plate locking Oil load plug (flanged) Oil unload (Ch.
Air-injection 50 cc TECHNICAL DATA CYLINDER + PISTON + RINGS Item: Piston to cylinder clearance Piston diam. Standard: mm (in) Airinjection 0.028-0.040 (0.0011-0.0016) 40.966-40.972 (*) (1.6128-1.6131) Selection B 40.972-40.978 (*) (1.6131-1.6133) Air- Selection C 40.978-40.984 injection (*) (1.6133-1.6135) Selection A Limit: mm (in) 0.100 (0.0039) 40.912 (1.6107) 40.918 (1.6109) 40.924 (1.6112) Measure 18 mm (0.7) from the outer edge Cylinder bore 41.000-41.006 (1.6141-1.6144) Selection B 41.
Air-injection 50 cc CYLINDER + PISTON + RINGS Item: Port at the end of the unassembled segment Port at the end of the segment fitted into the cylinder Segment/slot clearance Piston pin housing bore on piston Piston pin outer diameter Release 00 / 2002 - 09 Standard: mm (in) Air1°-2° injection T Air1°-2° injection T Airinjection 1°-2° Limit: mm (in) 4.5 (0.18) 3.6 (0.14) 0.25 - 0.40 (0.0098 - 0.0157) 0.70 (0.027) 0.036 - 0.076 (0.0014 - 0.0030) - Approx. Airinjection 12.002 - 12.010 (0.
Air-injection 50 cc CONROD + CRANKSHAFT Item: Connecting rod small end diameter Width from crank arm to arm (A) Misalignment limit (C) Side clearance of connecting rod big end (D) Standard: mm (in) Limite: mm (in) Airinjection 16.003 - 16.011 (0.6300 - 0.6304) 36.0 ± 0.05 16.040 (0.6315) Airinjection 37.95 - 38.10 (1.494 - 1.5) - Measured between two opposite points Airinjection 0.15 - 0.75 (0.0059 - 0.029) 0.03 (0.001) - Standard crank width Release 00 / 2002 - 09 Chapter.
Air-injection 50 cc CLUTCH Item: Standard: mm (in) Clutch shoe thickness 110.00 - 110.15 (4.331 - 4.337) 3.0 (0.12) Limit:mm (in) 110.50 (4.350) 2.0 (0.08) Clutch engagement 3200 ± 200 rpm - Clutch lock-up 6700 ± 300 rpm - Clutch wheel inner diameter OIL PUMP Item: Specification: Ri = 26.3 ± 2.6 Ω a 20° C Inner coil TRANSMISSION Item: Standard: mm (in) Reduction ratio Variable 2.9 - 0.75 - 51/15 x 67 x 14 - 18.4 (0.724) 17.4 (0.685) 110 (4.33) 104.5 (4.114) 17 (0.669) 16.5 (0.
Air-injection 50 cc OIL CHART Transmission oil (recommended): F.C.,SAE 75W - 90 or GEAR SYNTH, SAE 75W - 90. Or alternatively branded oils with equivalent or better performance than A.P.I. GL-4. Mixer oil (recommended): GREEN HIT 2 or CITY 2T. Or alternatively branded oils with equivalent or better performance than ISO-L-ETC++,A.P.I.
Air-injection 50 cc SPECIAL ENGINE TOOLS UK Illustration Release 00 / 2002 - 09 Tool code Name/function or use 8140229 Engine support. 8140429 Tool for fitting the teflon ring onto the air injector. 8140430 Tool for fitting the teflon ring onto the air injector. 8140431 Air injector extractor. Chapter.
Air-injection 50 cc SPECIAL ENGINE TOOLS UK Illustration Release 00 / 2002 - 09 Tool code Name/function or use 8140228 Adapter plate for flywheel and crankcase extraction. 8140227 Reduction gear for bearing assembly. 8140225 Reduction gear for crankcase traction. 8140226 Spacer for crankcase centering. Chapter.
Air-injection 50 cc SPECIAL ENGINE TOOLS UK Illustration Tool code Name/function or use 8140488 Release 00 / 2002 - 09 Fuel-air pressure gauge. Chapter.
Air-injection 50 cc LAMINAR VALVE A B Measure clearance (A) between laminar valve and its housing and size (B). If clearance (A) is in excess of 0.2 mm (0.008 in), replace the laminar valve. (B) size is at least 1 mm (0.04 in). 1 2 Tighten the gas-wire adjuster and the return-nut (1) carefully. If the nut is tightened to quickly, the threaded pawl plastic housing may break (2). Release 00 / 2002 - 09 Chapter.
aprilia Air-injection 50 cc INJECTION TROUBLESHOOTING TROUBLESHOOTING SHAFT (DOUBLE CHECK THE MALFUNCTION BEFORE REPLACING ANY PART) FUNCTIONAL PHASE 1 - Turn the key to the “ON” position When the start button is pressed, does the engine turn over? 2 - Does the control LED stay on? NO YES NO YES With the key in the “ON” position, is there power (12 Volt) between the two terminals of the injection control connector led? - Make sure the battery is charged Check the battery terminals Check the 15 A
aprilia Air-injection 50 cc INJECTION TROUBLESHOOTING (DOUBLE CHECK THE MALFUNCTION BEFORE REPLACING ANY PART) If the starter motor does not start or turns slowly 4 - Does the starter motor work properly when you press the starter button? NO YES - Make sure the battery is charged - Check battery connections - Check the electric plant against the workshop drawing for the SR 50 watercooled model (starter motor) - (Check the earth connection to the starter motor) 5 - Does the engine start up normally? NO
aprilia Air-injection 50 cc INJECTION TROUBLESHOOTING (DOUBLE CHECK THE MALFUNCTION BEFORE REPLACING ANY PART) Has the pre-delivery procedure been followed for a new vehicle? 6 - Does the engine idle normally? NO 1- Prime the petrol pump (each time it is replaced) by: a) switching to “ON” b) during the 5 seconds that the petrol pump is working press and release the tank/ pump hose repeatedly c) switch to “OFF” as soon as the petrol pump stops running d) switch back to “ON” e) repeat the sequence 8-10 t
aprilia Air-injection 50 cc INJECTION TROUBLESHOOTING (DOUBLE CHECK THE MALFUNCTION BEFORE REPLACING ANY PART) 7 - Does the vehicle accelerate normally (minimum acceleration)? NO YES - General check-up with Game-Boy and reset errors (butterfly valve at “O” if required) - Check the battery voltage - Replace the spark plug - Check Plug lead - Check the pick-up wiring - Check ECU.
aprilia Air-injection 50 cc INJECTION TROUBLESHOOTING (DOUBLE CHECK THE MALFUNCTION BEFORE REPLACING ANY PART) 9 - Half-open the throttle: does the vehicle maintain speed? NO YES - General check-up with Game-Boy and reset errors (butterfly valve at “O” if required) - Check the battery voltage - Replace the spark plug - Check Plug lead - Check the pick-up wiring - Check ECU.
aprilia Air-injection 50 cc INJECTION TROUBLESHOOTING (DOUBLE CHECK THE MALFUNCTION BEFORE REPLACING ANY PART) 11 - Does the engine work properly ticking over at minimum? NO - General diagnostics by Game-boy Check the battery voltage Replace the spark plug Check Plug lead Check the pick-up wiring Check ECU.
aprilia Air-injection 50 cc INJECTION TROUBLESHOOTING (DOUBLE CHECK THE MALFUNCTION BEFORE REPLACING ANY PART) CHECKING THE PRESSURE OF THE AIR AND FUEL CIRCUITS Fit the pressure gauge to the petrol circuit, between fuel pump and fuel rail To discharge air from the circuit: - switch to “ON” - nudge the starter motor so it switches on momentarily - the pressure of the fuel circuit should be 2.5 ± 2.
aprilia Air-injection 50 cc INJECTION TROUBLESHOOTING (DOUBLE CHECK THE MALFUNCTION BEFORE REPLACING ANY PART) During cranking check the maximum compressor pressure, blocking the delivery hose between the pressure gauge fuel rail.
aprilia Air-injection 50 cc (DOUBLE CHECK THE MALFUNCTION BEFORE REPLACING ANY PART) INJECTION TROUBLESHOOTING DESCRIPTION OF FAULTS FLASHING NUMBER 1 2 3 4 5 6 Overheated engine Fault in the phonic wheel FAULT PRIORITY 1 2 ENGINE CHECK - - Twin error of alignment, throttle sensor (TPS) Error of alignment, primary throttle sensor (TPS) 2 POSSIBLE CAUSE Damaged thermostat Check thermostat Damaged radiator Check radiator Damaged hose Check hose Inverted pickup wires Check wiring
aprilia Air-injection 50 cc (DOUBLE CHECK THE MALFUNCTION BEFORE REPLACING ANY PART) DESCRIPTION OF FAULTS FLASHING NUMBER FAULT PRIORITY ENGINE CHECK POSSIBLE CAUSE Battery voltage too low 9 10 11 Inadequate battery voltage or ECU disconnected Low voltage Faulty oil pump Air injector fault 1 1 2 Check the battery charge. Check and restore battery connections if necessary.
aprilia Air-injection 50 cc (DOUBLE CHECK THE MALFUNCTION BEFORE REPLACING ANY PART) DESCRIPTION OF FAULTS FLASHING NUMBER 12 Fuel injector fault FAULT PRIORITY 2 POSSIBLE CAUSE ENGINE CHECK Connectors Check connectors Damaged wires Check the continuity (R=0 Ohm) of the yellow/red wire between the fuel injector and ECU. Check the voltage (12V) between the red/black wire and the negative pole of the battery.
aprilia Air-injection 50 cc (DOUBLE CHECK THE MALFUNCTION BEFORE REPLACING ANY PART) DESCRIPTION OF FAULTS FLASHING NUMBER FAULT PRIORITY ENGINE CHECK POSSIBLE CAUSE Led for rev limit switch (if on, does not indicate a fault) 15 Rev limit switch triggered 2 Maximum speed limit 16 Fault to sensor feed circuit ECU Low voltage 3 - 17 Variator threshold exceeded 3 Rev limit 18 Temperature sensor fault (feed with current too low) - 19 Temperature sensor fault (feed with current too high) -
DISASSEMBLY SEQUENCE 10 V-BELT - CLUTCH - PRIMARY AND SECONDARY PULLEY 10 Nm (1 kgm) 26 N G 29 25 27 N 28 22 23 37 G 21 24 20 50 Nm (5 kgm) 38 9 50 Nm (5 kgm) 36 35 10 Nm (1 kgm) 2 15 8 17 16 19 18 13 14 3 12 CLUTCH 31 O.C. G L 7 31B 1A 6 4 5 N 10 Nm (1 kgm) 50 Nm (5 kgm) 31A Remove the 8 screws (1) retaining the T sleeves (1A), loosen the clamp (1B) and remove the variator cover (2). Remove the 6-sided nut (3), spacer 4), toothed cup (5) spacer (6).
N OM O.C. OBM G L 3 1 : New item : Engine oil : Gearbox oil : Molybdenum bisulphuroil : Grease : Loctite 8 6 DISASSEMBLY SEQUENCE COOLING UNIT Remove the 4 screws (1) and aeration cover (2). Remove the 2 screws (3) and fan conveyor (4). Remove the 3 screws (5), retain the T sleeves (6) and remove the fan (7). Remove the 3 screws (8) and the base of the fan (9). 5 6 C.A. GENERATOR 1 40 Nm (4 kgm) 11 2 12 8 5 Nm (0.5 kgm) 3 14 5 15 5 Nm (0.5 kgm) 6 17 9 4 Disconnect connectors (10).
DISASSEMBLY SEQUENCE INJECTION UNIT Empty the fuel tank Disconnect the wires Remove the 2 flanged screws (1). Remove the input valve (2). Remove the air injector using the proper tool (3). Slide off the O rings (4), (5). 6 DANGER 3 If connector hoses are removed (after removing the clamps), be very careful when refitting the high pressure hose (6) (maximum pressure 8-10 bar). 5 2 4 1 6-7 Nm (0.6-0.7 kgm) N OM O.C.
DISASSEMBLY SEQUENCE 17 17 22 HEAD - CYLINDER - PISTON 23 18 Remove the 2 screws (1), retain the 2 T sleeves (2). Remove the 2 screws (3). Remove the LH cylinder cover (4) and RH cover (5). Remove spark plug (6) and thermostat (7). Remove the four tightening head nuts (8). Remove head (9), head gasket (10), cylinder (11), base gas ket (12). Remove the pin stop (13). Slide out pin (14) and piston (15). Remove rings (16). 24 21 5 Nm (0.5 kgm) 5 OM 19 N OM 20 14 13 11 7 N 6-9 Nm (0.6-0.
11 13 DISASSEMBLY SEQUENCE G 4-5 Nm (0.4-0.5 kgm) 1 AIR COMPRESSOR 1 Remove the 4 screws (1) without losing the washers (2). Remove the compressor (3) from the guard. Remove the OR (4). Unscrew the compressor connector (5). 2 G L N 3 10 OM G N OM COVER AND CRANKCASE 14 15 5 12 G L N G 6 Remove the six cover screws (6). Separate the RH half (7) from the LH half (8) of the cover. Remove the gasket (9). Remove the crankcase (10) from the RH half.
Produced and printed by Studio Gallo Design srl Via Mogno,34/1 35012 Camposampiero (PD) Italy tel. 049 - 9303475 fax 049 - 9317954 www.stgallo.it e-mail: design@stgallo.
