Professional Documents
Culture Documents
00/2004-10
www.serviceaprilia.com
workshopmanual
UK
8140816
INTRODUCTION
SR 50
INTRODUCTION 0
0-1
INTRODUCTION
SR 50
SUMMARY
0.1. FOREWORD..................................................................................................................................................... 3
0.1.1. FOREWORD ............................................................................................................................................. 3
0.1.2. REFERENCE MANUALS .......................................................................................................................... 4
0.1.3. ABBREVIATIONS/SYMBOLS/CONVENTIONS ........................................................................................ 5
0-2
INTRODUCTION
SR 50
0.1. FOREWORD
0.1.1. FOREWORD
- This manual provides the information required for normal servicing.
- This publication is intended for use by aprilia Dealers and their qualified mechanics; many concepts have been
omitted on purpose as their inclusion would be superfluous. Since complete mechanical explanations have not been
included in this manual, the reader must be familiar with basic notions of mechanics, as well as with basic repair
procedures. Without such familiarity, repairs and checks could be ineffective and even hazardous. Since not all
vehicle inspection and repair procedures are described in details, pay utmost attention to avoid damages to
components or people. aprilia s.p.a. undertakes to constantly improve the design of its products and their literature
to ensure that the customer is satisfied of the product. The main technical modifications and changes in repair
procedures are communicated to all aprilia dealers and agencies worldwide. These changes will be applied to the
next issues of this manual. Should you need assistance or clarifications about the inspection and repair procedures,
please contact the aprilia SERVICE DEPT., they will be glad to give you any information on the matter, or supply
you with any detail on updates and technical changes applied to the vehicle.
aprilia s.p.a. reserves the right to make changes to its products at any time, barring any such changes as may alter the
essential features of a product as specified in the relevant manual.
All rights of electronic storage, reproduction and total or partial adaptation with any means reserved for all Countries.
Third parties' products are only mentioned for information purposes, and constitute no engagement.
aprilia s.p.a. is not liable in any way for the performance or use of these products.
DECA S.r.l.
via Risorgimento, 23/1 - 48022 Lugo (RA) - Italy
Tel. +39 - 0545 35235
Fax +39 - 0545 32844
E-mail: deca@decaweb.it
www.decaweb.it
On behalf of:
aprilia s.p.a.
via G. Galilei, 1 - 30033 Noale (VE) - Italy
Tel. +39 – (0)41 58 29 111
Fax +39 – (0)41 58 29 190
www.aprilia.com
www.serviceaprilia.com
0-3
INTRODUCTION
SR 50
Version
aprilia part# (description)
5574_00
OWNER'S MANUALS
aprilia part#
8202397
8202441
8202442
8202439
aprilia part#
8140818
8140821
8140819
8140820
8140822
8CM0067
aprilia part#
8140645
8140646
8140647
8140648
8140649
8CM006
aprilia part#
8140812
8140815
8140813
8140814
8140816
8140817
8CM0064
8CM0065
0-4
INTRODUCTION
SR 50
0.1.3. ABBREVIATIONS/SYMBOLS/CONVENTIONS
# = number
< = less than
> = greater than
≤ = less than or equal to
≥ = more than or equal to
~ = approximately
∞ = infinity
°C = degrees Celsius (centigrade)
°F = degrees Fahrenheit
± = plus or minus
a.c = alternating current
A = Ampere
Ah = Ampere per hour
API = American Petroleum Institute
AT = high voltage
AV/DC = Anti-Vibration Double Countershaft
bar = pressure measurement (1 bar = 100 kPa)
d.c. = direct current
cc = cubic centimetres
CO = carbon monoxide
CPU = Central Processing Unit
DIN = German industrial standards (Deutsche Industrie Norm)
DOHC = Double Overhead Camshaft
ECU = Electronic Control Unit
rpm = revolutions per minute
HC = unburnt hydrocarbons
ISC = Idle Speed Control
ISO = International Standardisation Organisation
kg = kilograms
kgm = kilogram metre (1 kgm = 10 Nm)
km = kilometres
km/h = kilometres per hour
kΩ = kilo Ohm
kPa = kiloPascal (1 kPa = 0.01 bar)
KS = clutch side (from the German "Kupplungseite")
kW = kilowatt
l = litres
LAP = racetrack lap
LED = Light Emitting Diode
LEFT SIDE = left side
m/s = metres per second
max = maximum
mbar = millibar (1 mbar = 0.1 kPa)
mi = miles
MIN = minimum
MPH = miles per hour
MS = flywheel side (from the German "Magnetoseite")
MΩ = MegaOhm
N.A. = Not Available
N.O.M.M. = Motor Octane Number
N.O.R.M. = Research Octane Number
Nm = Newton metre (1 Nm = 0.1 kgm)
Ω = ohm
PICK-UP = pick-up
BDC = Bottom Dead Centre
TDC = Top Dead Centre
PPC = Pneumatic Power Clutch
RIGHT SIDE = right side
SAE = Society of Automotive Engineers
SAS = Secondary Air System
0-5
INTRODUCTION
SR 50
0-6
GENERAL INFORMATION
SR 50
GENERAL INFORMATION 1
1-1
GENERAL INFORMATION
SR 50
SUMMARY
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............................................................................................................................................ 5
1.2.1. BASIC SAFETY RULES ............................................................................................................................ 5
1.3. DANGEROUS ELEMENTS............................................................................................................................... 8
1.3.1. WARNINGS ............................................................................................................................................... 8
1.4. RUNNING-IN .................................................................................................................................................. 11
1.4.1. RUNNING-IN ........................................................................................................................................... 11
1.5. VEHICLE IDENTIFICATION ........................................................................................................................... 12
1.5.1. POSITION OF THE SERIAL NUMBERS ................................................................................................. 12
1-2
GENERAL INFORMATION
SR 50
VERSION:
1-3
GENERAL INFORMATION
SR 50
Safety warning. This symbol appears, whether in the manual or on the vehicle itself, to indicate a
personal injury hazard. Non-compliance with the indications given in the messages preceded by this
symbol may result in grave risks for your and other people’s safety and for the vehicle!
DANGER
Indicates a potential hazard which may result in serious injury or even death.
WARNING
Indicates a potential hazard which may result in minor personal injury or damage to the vehicle.
CAUTION The word "CAUTION" in this manual identifies important information or instructions.
1-4
GENERAL INFORMATION
SR 50
DANGER
Exhaust gases contain carbon monoxide, which is extremely toxic if inhaled and may cause loss of
consciousness or even lead to death.
FUEL
DANGER
The fuel used to operate engines is highly flammable and becomes explosive under particular
conditions.
Refuelling and engine service should take place in a well-ventilated area with the engine stopped.
Do not smoke when refuelling or in the proximity of sources of fuel vapours, avoid flames, sparks and
any element that could ignite fuel or provoke explosions.
HIGH-TEMPERATURE COMPONENTS
The engine and the components of the exhaust system become very hot and remain hot for some time after the engine
has been stopped.
Before handling these components, wear insulating gloves or wait until the engine and the exhaust system have cooled
down.
DANGER
Wear latex gloves when servicing.
Gear fluid may cause serious damage to the skin if handled daily and for long periods.
Wash your hands carefully after use.
Take it to the filling station where you usually buy it or to an oil salvage centre.
Wear latex gloves when servicing.
BRAKE FLUID
WARNING
When handling the brake fluid, take care not to spill it on the plastic, rubber or painted parts, since it
can damage them. When carrying out the maintenance operations on the braking system, use a clean
cloth to cover these parts.
Always wear safety goggles when working on the braking system.
The brake fluid is highly irritant. Avoid contact with your eyes.
If the brake fluid gets in contact with your eyes, carefully wash them with fresh water and immediately
seek medical advice.
1-5
GENERAL INFORMATION
SR 50
DANGER
The battery electrolyte is a toxic, caustic substance containing sulphuric acid and thus able to cause
severe burns in case of contact with the skin.
Always wear tight gloves and protective clothes when handling this fluid.
In case of contact with skin, rinse with plenty of fresh water.
Always use a protection for your eyes since even a very small amount of the battery fluid can cause
blindness. In the event of contact with your eyes, carefully wash them with water for fifteen minutes
and then consult immediately an eye specialist.
Should you accidentally drink some fluid, drink abundant water or milk, then drink magnesia milk or
vegetable oil and immediately seek medical advice.
The battery gives off explosive gases and must be kept away from flames and sources of ignition or
heat; do not smoke near the battery.
Make sure the room is well-aerated when servicing or recharging the battery.
DANGER
Using bare flames is strictly forbidden when working on the motorcycle. Before servicing or
inspecting the motorcycle: stop the engine and remove the key from the ignition switch; allow for the
engine and exhaust system to cool down; where possible, lift the motorcycle using adequate
equipment placed on firm and level ground. Be careful of any parts of the engine or exhaust system
which may still be hot to the touch to avoid scalds or burns.
Do not put any vehicle parts into your mouth: vehicle components are not edible and some of them
are harmful or even toxic.
Unless expressly specified otherwise, assemblies are reassembled by reversing the dismantling
procedure. Where a procedure is cross-referred to relevant sections in the manual, proceed sensibly
to avoid disturbing any parts unless strictly necessary. Do not polish matt-painted surfaces with
polishing paste.
Never use fuel instead of solvent to clean the motorcycle.
Do not clean any rubber or plastic parts or the seat with alcohol, petrol or solvents. Clean with water
and mild detergent.
Always disconnect the battery negative (-) lead before soldering any electrical components.
When two or more persons service the same motorcycle together, special care must be taken to avoid
personal injury.
For further warnings, see (DANGEROUS ELEMENTS).
1-6
GENERAL INFORMATION
SR 50
DANGER
Never reuse a circlip or snap ring. These parts must always be renewed once they have been
disturbed.
When fitting a new circlip or snap ring, take care to move the open ends apart just enough to allow
fitment to the shaft.
Make it a rule to check that a newly-fitted circlip or snap ring has located fully into its groove.
Never clean a bearing with compressed air.
CAUTION All bearings must rotate freely with no hard spots or noise. Replace any bearings that do not meet these
requirements.
- Use ORIGINAL aprilia SPARE PARTS only.
- Use the specified lubricants and consumables.
- Where possible, lubricate a part before assembly.
- When tightening nuts and bolts, start with the largest or innermost nut/bolt and observe a cross pattern. Tighten
evenly, in subsequent steps until achieving the specified torque.
- Replace any self-locking nuts, gaskets, seals, circlips or snap rings, O-rings, split pins, bolts and screws which have
a damaged thread.
- Lubricate the bearings abundantly before assembly.
- Make it a rule to check that all components you have fitted are correctly in place.
- After repairing the motorcycle and after each service inspection, perform the preliminary checks, and then ride the
motorcycle in a private estate area or in a safe area away from traffic.
- Clean all mating surfaces, oil seal edges and gaskets before assembly. Apply a thin layer of lithium grease along the
edges of oil seals. Fit oil seals and bearings with the marking or serial number facing outwards (in view).
ELECTRICAL CONNECTORS
To disconnect the electrical connectors, follow the procedures below. Failure to comply with these procedures may lead
to irreparable damage to the connector and the wiring as well.
If present, press the special safety hooks.
WARNING
Do not pull cables to disconnect the two connectors.
• Grasp the two connectors and disconnect them by pulling them in the two opposite directions.
• In case of dirt, rust, moisture, etc.., thoroughly clean the inside of the connectors with compressed air.
• Make sure that the cables are correctly fitted inside the connector terminals.
CAUTION The two connectors have just one correct positioning. Make sure to position them in the right direction.
• Then fit the two connectors. Make sure they are correctly coupled (a click will be heard if hooks are present).
DANGER
Always remember that the tightening torque settings of all wheel, brake, wheel shaft and other
suspension parts play a fundamental role to ensure vehicle safety. Make sure that these values are
always within the specified limits.
Check fastening parts tightening torque settings at regular intervals. Upon reassembly, always use a
torque wrench.
Failure to comply with these recommendations could lead to the loosening and detachment of one of
these parts with a consequent locking of the wheel or other serious troubles affecting the vehicle
manoeuvrability, and thus the risk of falls and serious injuries or death.
1-7
GENERAL INFORMATION
SR 50
FUEL
DANGER
The fuel used to operate engines is highly flammable and becomes explosive under particular
conditions.
Refuelling and engine service should take place in a well-ventilated area with the engine stopped.
Do not smoke when refuelling or in the proximity of sources of fuel vapours, avoid flames, sparks and
any element that could ignite fuel or provoke explosions.
Take care not to spill fuel out of the filler, or it may ignite when in contact with hot engine parts.
In the event of accidental fuel spillage, make sure the affected area is fully dry before starting the
engine. Fuel expands from heat and when left under direct sunlight.
Never fill the fuel tank up to the brim. Tighten the filler cap securely after each refuelling.
Avoid contact with skin. Do not inhale vapours. Do not swallow fuel. Do not transfer fuel between
different containers using a hose.
DO NOT DISPOSE OF FUEL IN THE ENVIRONMENT.
KEEP AWAY FROM CHILDREN.
Use only unleaded petrol with 95 RON and 85 MON octane rating minimum.
LUBRICANTS
DANGER
A good lubrication ensures the vehicle safety.
Failure to keep the lubricants at the recommended level or the use of a non-suitable new and clean
type of lubricant can lead to the engine or gearbox seizure, thus causing serious accidents, personal
injury or even death.
Gear fluid may cause serious damage to the skin if handled daily and for long periods.
Wash your hands carefully after use.
Do not dispose of oil in the environment.
Take it to the filling station where you usually buy it or to an oil salvage centre.
WARNING
When filling the vehicle with this oil, take care not to spill it out. Immediately clean spilt oil, or it might
damage the vehicle paintwork.
In case of contact with oil, the tyres surface will become very slippery, thus becoming a serious
danger for your safety.
In case of leaks, do not use the vehicle. Check and trace the cause of leaks and proceed to repair.
Engine oil
DANGER
Engine oil may cause serious damage to the skin if handled daily and for long periods.
Wash your hands carefully after use.
Do not dispose of oil in the environment.
Dispose of engine oil through the nearest waste oil reclamation firm or through the supplier.
Wear latex gloves when servicing.
DANGER
Front suspension response can be modified to a certain extent by changing damping settings and/or
selecting a particular grade of oil. Standard oil: SAE 20 W. Choose suitable viscosity grades according
to the desired set-up (SAE 5W softer, 20W less soft).
The two grades can also be mixed in varying solutions to obtain the desired response.
1-8
GENERAL INFORMATION
SR 50
BRAKE FLUID
CAUTION This vehicle is fitted with front and rear disc brakes. Each braking system is operated by an independent
hydraulic circuit. The information provided below applies to both braking systems.
DANGER
Do not use the vehicle in case brakes are worn out or do not work properly. The brakes are the parts
that most ensure your safety and for this reason they must always be perfectly working. Failure to
comply with these recommendations will probably lead to a crash or an accident, with a consequent
risk of personal injury or death.
A wet surface reduces brakes efficiency.
DANGER
In case of wet ground the braking distance will be doubled, since both brakes and tyre grip on the
road surface are extremely reduced by the water present on the road surface.
Any water on brakes, after washing the vehicle or driving on a wet road surface or crossing puddles
or gips, can wet brakes so as to greatly reduce their efficiency.
Failure to comply with these recommendations may lead to serious accidents, with a consequent risk
of severe personal injuries or death.
Brakes are critical safety components. Do not ride the vehicle in case brakes are not working at their
best.
Check for brakes proper operation before every trip.
Brake fluid is an irritant. Avoid contact with eyes or skin.
In the event of accidental contact, wash affected body parts thoroughly. In the event of accidental
contact with eyes, contact an eye specialist or seek medical advice.
DO NOT RELEASE BRAKE FLUID INTO THE ENVIRONMENT.
KEEP AWAY FROM CHILDREN.
When handling brake fluid, take care not to spill it onto plastic or paint-finished parts or they will
damage.
DANGER
Do not use any brake fluids other than the specified type. Never mix different types of fluids to top up
level, as this will damage the braking system.
Do not use brake fluid from containers which have been kept open or in storage for long periods.
Any sudden changes in play or hardness in the brake levers are warning signs of problems with the
hydraulic circuits.
Ensure that the brake discs and brake linings have not become contaminated with oil or grease. This
is particularly important after servicing or inspections.
Make sure the brake lines are not twisted or worn.
Prevent accidental ingress of water or dust into the circuit.
Wear latex gloves when servicing the hydraulic circuit.
DISC BRAKES
DANGER
The brakes are the parts that most ensure your safety and for this reason they must always be
perfectly working; check them before every trip.
A dirty disc soils the pads.
Dirty pads must be replaced, while dirty discs must be cleaned with a high-quality degreaser.
Perform the maintenance operations with half the indicated frequency if the vehicle is used in rainy or
dusty areas, on uneven surfaces or for racing.
Check brake pads for wear.
When the brake pads wear out, the level of the fluid decreases to automatically compensate for their
wear.
The front brake fluid reservoir is located on the right handlebar, near the front brake lever.
The rear brake fluid reservoir is located under the right fairing.
Do not use the vehicle if the braking system leaks fluid.
1-9
GENERAL INFORMATION
SR 50
COOLANT
DANGER
Coolant is toxic when ingested and is an irritant, contact with eyes or skin may cause irritation.
In the event of contact with your skin or eyes, rinse repeatedly with abundant water and seek medical
advice. In the event of ingestion, induce vomiting, rinse mouth and throat with abundant water and
seek medical advice immediately.
DO NOT RELEASE INTO THE ENVIRONMENT.
KEEP AWAY FROM CHILDREN.
DANGER
Take care not to spill coolant onto hot engine parts. It may ignite and produce invisible flames. Wear
latex gloves when servicing.
Do not ride when coolant is below the minimum level.
Coolant mixture is a 50% solution of water and antifreeze. This is the ideal solution for most operating temperatures and
provides good corrosion protection.
This solution is also suited to the warm season, as it is less prone to evaporative loss and will reduce the need for top-
ups.
In addition, less water evaporation means fewer minerals salts depositing in the radiator, which helps preserve the
efficiency of the cooling system.
When the temperature drops below zero degrees centigrade, check the cooling system frequently and add more
antifreeze (up to 60% maximum) to the solution, if needed.
Use distilled water in the coolant mixture. Tap water will damage the engine.
Refer to the chart given below and add water with the quantity of antifreeze to obtain a solution with the desired freezing
point:
TYRES
WARNING
If tyres are excessively inflated, the vehicle will be hard, difficult and uncomfortable to ride.
In addition, the roadworthiness, mainly on wet surfaces and during cornering, will be impaired.
Flat tyres (insufficient pressure) can slip on the rim and make you lose the control of the vehicle.
In this case too, both vehicle roadworthiness, manoeuvrability and brake efficiency will be impaired.
Tyres changing, repair, maintenance and balancing must be carried out by specialized technicians
using suitable equipment.
When new, tyres can have a thin slippery protective coating. Drive carefully for the first kilometres
(miles).
Never use rubber treating substances on tyres.
In particular, avoid contact with fluid fuels, leading to a rapid wear.
In case of contact with oil or fuel, do not clean but change the tyres.
DANGER
Some of the factory-assembled tyres of this vehicle are provided with wear indicators.
There are several kinds of wear indicators.
For more information on how to check the wear, contact your Dealer.
Visually check if the tyres are worn and in this case have them changed.
If a tyre deflates while driving, stop immediately.
Avoid hard brakings or moves and do not close throttles too abruptly.
Slowly close the throttle grip, move to the edge of the road and use the engine brake to slow down
until coming to a halt.
Failure to comply with these recommendations may lead to accidents, with a consequent risk of
personal injuries or death.
Do not install tyres with air tube on rims for tubeless tyres and vice versa.
1 - 10
GENERAL INFORMATION
SR 50
1.4. RUNNING-IN
1.4.1. RUNNING-IN
Correct engine running-is essential to ensuring proper performance and durability.
Twisty, hilly roads are ideal for an effective running-in of engine, suspension and brakes.
Vary speed frequently during the running-in period.
This will allow engine parts to be alternately loaded and unloaded, allowing them to cool down when unloaded.
While it is important to put some stress on engine components during running-in, it is equally important to avoid extreme
load conditions.
WARNING
Only after the first 500 km (312 mi) of running-in is it possible to obtain the best acceleration
performance from the vehicle.
WARNING
After the first 1000 km (625 mi), carry out the checking operations indicated in the column "After
running-in", see REGULAR SERVICE INTERVALS CHART, in order to avoid hurting yourself or other
people and/or damaging the vehicle.
1 - 11
GENERAL INFORMATION
SR 50
ENGINE NUMBER
1 - 12
PERIODIC MAINTENANCE
SR 50
PERIODIC MAINTENANCE 2
2-1
PERIODIC MAINTENANCE
SR 50
SUMMARY
2.1. SPECIFICATIONS ............................................................................................................................................ 3
2.1.1. TECHNICAL DATA.................................................................................................................................... 3
2.1.2. SCHEDULED MAINTENANCE CHART .................................................................................................... 5
2.1.3. LUBRICANT TABLE .................................................................................................................................. 6
2.1.4. TIGHTENING TORQUE SETTINGS ......................................................................................................... 7
2.1.5. MULTIFUNCTION DIGITAL COMPUTER IE 361 – IE 50........................................................................ 11
2.1.6. MULTIFUNCTION DIGITAL COMPUTER C 364..................................................................................... 18
2.2. SCHEDULED MAINTENANCE....................................................................................................................... 19
2.2.1. BRAKING SYSTEM................................................................................................................................. 19
2.2.2. CLEANING THE AIR FILTER .................................................................................................................. 23
2.2.3. COOLANT ............................................................................................................................................... 24
2.2.4. GEAR FLUID IE361 – C364 .................................................................................................................... 26
2.2.5. GEAR FLUID IE50 ................................................................................................................................... 28
2.2.6. MIXER OIL IE361 – C364........................................................................................................................ 30
2.2.7. MIXER OIL IE50 ...................................................................................................................................... 31
2-2
PERIODIC MAINTENANCE
SR 50
2.1. SPECIFICATIONS
2.1.1. TECHNICAL DATA
DIMENSIONS
Max. length (with rear mudguard extension) 1860 mm (73.2 in.)
Max. Width 705 mm (27.8 in.)
Max. height (to the headlight fairing) 1120 mm (44.1 in.)
Seat height 795 mm (31.3 in.)
Wheelbase 1290 mm (50.8 in.)
Wheelbase - 1260 mm (49.6 in.)
Minimum ground clearance 100 mm (3.94 in.)
Loadless weight (in running order) 108 kg (238 lb)
ENGINE
Type 2 strokes
Model C364M
Model C361M
Model Aprilia engine ditech
Number of cylinders horizontal single-cylinder
Total displacement 49.38 cu. cm (3.01 cu.in)
Bore/stroke / 40 mm /39.3 mm (1.57 in /1.55 in).
Bore/stroke 41 mm /37.4 mm (1.61 in /1.47 in).
Compression ratio 12.1 ± 0.5 : 1
Compression ratio 11.50
Compression ratio 12.50
Starting electric + kick starter
Starting / Electric starter
Engine idling speed 1700 ± 100 rpm
Engine idling speed 2000 ± 50 rpm
Engine idling speed 1600 ± 100 rpm
Clutch automatic, dry centrifugal clutch
Gearbox automatic converter, stepless
Cooling system Liquid
CAPACITIES
Fuel (including reserve) 7 litres (12.7 pt)
Fuel reserve 1.2 litres (2.18 pt)
Gearbox oil 130 cu. cm (7.93 cu.in)
Gearbox oil / 75 cu. cm (4.58 cu.in)
Mixer oil (reserve included) 1.2 litres (2.18 pt)
Mixer oil reserve 0.2 litres (0.36 pt)
Coolant 1.2 litres (2.18 pt)
(50% water + 50% antifreeze with ethylene glycol)
Seat no. 1
(2 in the countries where a passenger is allowed)
Vehicle max. load (rider + luggage) 105 kg (231 lb)
Vehicle max. load (rider + passenger + luggage) 180 Kg (397 lb)
(in the countries where a passenger is allowed)
TRANSMISSION SYSTEM
Converter Stepless automatic converter
Primary V belt
Ratios
- minimum for stepless gearbox 3.07 / 3.07 / 2.90
- maximum for stepless gearbox 1.37 / 1.24 / 0.75
Final gears
CARBURETTOR
Model
- standard Dell’Orto PHVA 17.5
Channel Ø 17.5 mm (0.69 in.)
ELECTRONIC INJECTION FUEL FEED /
Model
- standard BING 71
Throttle Ø 18 mm (0.71 in.)
FUEL SYSTEM
Fuel unleaded fuel, in conformity with the DIN 51607 standard,
min. O.N. 95 (R.O.N.) and 85 (M.O.N.).
2-3
PERIODIC MAINTENANCE
SR 50
FRAME
Type Split single-beam
SUSPENSIONS
Front Telescopic fork
Travel 90 mm (3.54 in.)
Rear hydraulic monoshock
Travel 69 mm (2.72 in.)
BRAKES
Front Disc - Ø 190 mm (7.48 in) with hydraulic transmission.
Rear Disc - Ø 190 mm (7.48 in) with hydraulic transmission.
WHEEL RIMS
Type alloy
Front 3.50 x 13"
Rear 3.50 x 13"
TYRES
Type tubeless
Front 130/60 – 13" 53J
Rear 130/60 – 13" 53J
STANDARD INFLATION PRESSURE
Front 180 kPa (1.8 bar) (26 PSI)
Rear 200 kPa (2.0 bar) (29 PSI)
INFLATION PRESSURE WITH PASSENGER
(in the countries where this is allowed)
Front 180 kPa (1.8 bar) (26 PSI)
Rear 220 kPa (2.2 bar) (32 PSI)
IGNITION
Type C.D.I.
Type / T.D.I.
Spark advance 20 ° ± 3 ° before TDC.
Spark advance / mapped to rpm/a (a = throttle opening)
SPARK PLUG
Standard CHAMPION RN1C
Standard CHAMPION RG6YCA / RG6YC
Standard NGK-R CPR8E
As an alternative / NGK-R ZMR7AP (recommended) / CR8EKB / CR7EKB
Spark plug electrode gap 0.6 – 0.7 mm (0.024 – 0.028 in.)
Spark plug electrode gap / 0.9 mm (0.035 in.)
ELECTRIC SYSTEM
Battery with maintenance 12 V - 9 Ah
Fuses 7.5 A - 15 A
Fuses 10 A - 15 A
Fuses 10 A
Generator (with permanent magnet) 12 V - 70 W
Generator (with permanent magnet) 12 V - 165 W
Generator (with permanent magnet) 12 V - 140 W
BULBS
Low beam 12 V - 35 W
High beam 12 V - 35 W
Direction indicators 12 V – 10 W
Rear parking / stop light 12 V – 5 / 21 W
Instrument panel lights 12 V - LED
WARNING LIGHTS
High beam 12 V - LED
Direction indicators 12 V - LED
Fuel reserve 12 V - LED
Injection Check / 12 V - LED
2-4
PERIODIC MAINTENANCE
SR 50
Carry out the maintenance operations more frequently if you use the vehicle in rainy and dusty areas or on uneven
ground.
2-5
PERIODIC MAINTENANCE
SR 50
2-6
PERIODIC MAINTENANCE
SR 50
WARNING
The fastening elements listed should be tightened to the specified torque using a torque wrench and
applying LOCTITE ® where indicated.
Torque
Description Q.ty Type of fastener Tol. Note
(Nm)
Frame
Wheelhouse support to frame fastener 2 Screw M6x16 10 ±20%
Coil to connection plate fastener 2 Screw M4x20 3 ±20%
Fuel tank protector to frame fastener 2 Screw M5x16 2 ±20%
Wheelhouse to support fastener 2 Screw M6x16 4 ±20%
Radiator support to frame fastener 2 Screw M6x16 7 ±20%
Connecting rod
Connecting rod to frame and
2 Nut M10 42 ±20%
connecting rod to engine fastener
Connecting rod -
Connecting rod connection plates to
4 Screw M8x20 25 ±20%
frame fastener
Silent-block to connection plate
2 Screw M10x55 42 ±20%
fastener
Engine shaft fastener 1 Nut M12 60 ±20%
Stand
Stand fastener onto engine 1 Screw M8x25 25 ±20%
Stand fastener onto engine 1 Screw M8x70 25 ±20%
Fork
Steering nut fastener 1 Nut M32x1 10 ±20%
Adjust steering
Steering lock nut 1 Self-locking nut M32x1 110 -
play
Rear suspension
Shock absorber lower screw fastener 1 Screw M10x55 40 ±20%
Shock absorber upper screw fastener 1 Screw M10x35 50 ±20%
Engine
Self-tapping 3.9x14
Cover to crankcase cover fastener 4 0.5 -
plastic
Self-tapping 3.9x14
Inner disc to crankcase cover fastener 3 0.5 -
plastic
Engine
Converter unit cover fastener 4 Self-tapping screw M5 4 ±20%
Crankcase cover fastener 5 Screw M6x40 10 ±20%
Rear cover to crankcase cover
1 Screw M6x16 10 ±20%
fastener
Engine
Converter unit cover fastener 4 Self-tapping screw M5 4 ±20%
Allen cheese-headed
Converter cover to crankcase fastener 8 10 ±20%
screw M6x25
Filter box
Air box to bracket fastener ( –
2 M6x60 10 ±20%
)
Air box bracket to engine fastener
1 M6x40 10 ±20%
( – )
Air box bracket to engine fastener
1 M6x30 10 ±20%
( – )
Base cover fastener 3 Self-tapping 5x20 plastic 2 -
Self-tapping 3.9x14
Cap to cover fastener ( – ) 4 0.8 -
plastic
Hose tie to base fastener 1 Tie 25 - 45 0.4 -
Hose tie to throttle body fastener 1 Tie 25 - 45 2 -
2-7
PERIODIC MAINTENANCE
SR 50
Torque
Description Q.ty Type of fastener Tol. Note
(Nm)
Exhaust
Muffler flange to cylinder fastener 2 Nut M6 10 ±20%
Protection fastener onto muffler 2 Screw M6x16 10 ±20%
Muffler and mudguard to engine
1 Screw M8x85 27 ±10%
fastener
Muffler fastener onto engine 1 Screw M8x85 27 ±10%
Cooling system
Ties secured with air gun 2 Tie 17 - 25 3 -
Head pipe fastener onto radiator 1 Clamp D.16 – 24x8 2 ±20%
Front wheel
Allen crowned-head
Brake disc fastener 3 25 ±10%
screw M8x30
Wheel shaft fastener 1 Nut M12x1.25 50 ±10%
Wheel shaft clamp fastener 2 Screw M6 10 ±10%
Rear Wheel -
Allen crowned-head
Brake disc fastener 3 25 ±10%
screw M8x25
Allen cheese-headed
Wheel to hub fastener 3 50 ±20%
screw M10x55
Hub to engine fastener 1 Nut M16 130 ±10%
Rear wheel
Wheel to engine fastener 1 M14x1.5 110 ±10%
Front and rear brake
Hex. head screw flandrin
Front brake calliper fastener 2 27 ±10%
M 8x35
Allen crowned-head
Rear calliper fastener 2 27 ±10%
screw M8x35
Flanged hex.head screw
Rear brake fluid line tie fastener 1 10 ±20%
M6x35
Handlebar
Safety screw fastener for fork onto Flanged hex.head screw ±20%
1 25
handlebar M8x40
Allen cheese-headed ±20%
Handlebar clamp to fork fastener 1 50
screw M10x55
Allen chees-headed ±20%
Right and left mirror securing screw 2 25
screw M8x35
Brake master cylinders to handlebar ±20%
4 Screw M6x25 10
fastener
Front bodywork
Self-tapping 3.9x14
Door to wheelhouse fastener 2 0.8 -
plastic
Flanged hex.head screw
Front mudguard to insert rear fastener 2 1 -
M5x40
Allen crowned-head
Mudguard front fastener 2 2 ±20%
screw M5x16
Fastener for wheelhouse onto grid Self-tapping 4.2x16
10 1 -
frame side panels and under-platform crowned cheese-headed
Self-tapping 3.9x14
Scoops to side panels fastener 4 0.8 -
plastic
Allen crowned-head
Headlight to side panels fastener 4 1 ±20%
screw M4x16
Allen crowned-head
Radiator conveyor fastener 4 5 ±20%
screw M5x16 with collar
Grid frame to inner grid fastener 3 Self-tapping 2.9x12 0.3 -
Complete frame to side panels Self-tapping 3.9x14
6 0.8 -
fastener plastic
Self-tapping 4.2x16
Front cover to inner shield fastener 2 1 -
crowned cheese-headed
Inner shield to side panels and Self-tapping 4.2x16
10 1 -
platform fastener crowned cheese-headed
Side panels to inner shield upper Self-tapping 3.9x14
2 0.8 -
fastener plastic
Allen crowned-head
Inner shield to frame fastener 1 2 -
screw M5x16
Self-tapping 4.2x25
Bag hook to inner shield fastener 2 1 -
crowned cheese-headed
2-8
PERIODIC MAINTENANCE
SR 50
Torque
Description Q.ty Type of fastener Tol. Note
(Nm)
Centre bodywork
Passenger footboard platform to frame Allen crowned-head
4 2 ±20%
fastener screw M5x16
Allen crowned-head
Under-platform to platform fastener 2 2 ±20%
screw M5x16
Self-tapping 4.2x16
Under-platform to platform fastener 6 1 -
crowned cheese-headed
Allen crowned-head
Platform cover fastener 2 2 ±20%
screw M5x16
Allen crowned-head
Rh and Lh tunnel to platform fastener 2 2 ±20%
screw M5x16
Self-tapping 4.2x16
Rh and Lh tunnel to platform fastener 2 1 -
crowned cheese-headed
Allen crowned-head
Tool compartment to platform fastener 1 2 ±20%
screw M5x16
Rear bodywork
Tail guard and seat support assy Allen crowned-head
6 2 ±20%
fastener onto fuel tank protector screw M5x16
Number plate holder to fuel tank Allen crowned-head
4 2 ±20%
protector fastener screw M5x16
Allen crowned-head
Seat support assy to tunnel fastener 4 2 ±20%
screw M5x16
Tail guard to helmet compartment Self-tapping 4.2x16
14 0.8 -
fastener crowned cheese-headed
Allen crowned-head
Turn indicators to tail guard fastener 2 0.5 ±20%
screw M4x16
Allen crowned-head
Tail light to tail guard fastener 2 1 ±20%
screw M4x16
Grab handle to frame and to helmet Allen cheese-headed
4 10 ±20%
holder fastener screw M6x25
Allen crowned-head
Helmet compartment to frame fastener 2 7 ±20%
screw M6x16
Allen crowned-head
Rear mudguard to air box fastener 1 2 ±20%
screw M5x16 with collar
Rear cat's eye to number plate holder
2 Nut M14
fastener
Locks
Allen crowned-head
Seat latch to inner shield fastener 2 2 ±20%
screw M5x16
Levers to helmet compartment Allen crowned-head
2 4 ±20%
fastener screw M6x16
Lock to tunnel cover fastener 1 Narrow-head nut M19x1 4 -
Lever to tunnel cover lock fastener 1 M4x6 3 ±20%
Allen cheese-headed
Ignition lock to frame fastener 1 10 ±20%
screw M6x16
Seat
Seat bottom end to frame fastener 9 Self-tapping 5x14 plastic 1.5 -
Self-tapping 3.9x14
Box to lug fastener 6 0.7 -
plastic
Self-tapping 3.9x14
Box to lug fastener 2 0.5 -
plastic
ELECTRIC SYSTEM
Horn fastener 1 M6x16 10 ±20%
Voltage regulator fastener 2 M6x25 10 ±20%
Sensor support fastener 1 M6x16 7 ±20%
Ground cables fastener 1 M6x16 7 ±20%
Control unit fastener ( – ) 3 M5x16 5 ±20%
Coil connection plate to frame fastener 1 M6x12 10 ±20%
Crowned cheese-headed
Tail light glass fastener 1 1 -
screw M5x10
2-9
PERIODIC MAINTENANCE
SR 50
Torque
Description Q.ty Type of fastener Tol. Note
(Nm)
Instrument panel / Steering head
Instrument panel to support plate
3 Self-tapping 5x14 plastic 0.5 -
fastener
Allen crowned-head
Steering head to handlebar fastener 2 1 ±20%
screw M4x16
Self-tapping 3.9x14
Steering head to handlebar fastener 1 0.5 -
plastic
Instrument panel support plate to head Self-tapping 3.9x14
3 0.5 -
bottom end fastener plastic
Front support plate to instrument panel Self-tapping 3.9x14
5 0.5 -
support plate fastener plastic
Handlebar cover to steering head Self-tapping 3.9x14
4 0.5 -
bottom end fastener plastic
Turn indicators to support plate Self-tapping 3.9x14
4 0.5 -
fastener plastic
Self-tapping 3.9x14
Turn indicator covers fastener 2 0.5 -
plastic
Headlight fairing to front support plate Allen crowned-head
4 1 ±20%
fastener screw M5x20
Controls to handlebar fastener 4 Screw M5 1 -
Tanks
Fuel tank to helmet compartment Allen crowned-head
3 3 ±20%
fastener screw M5x16 with collar
Fuel pump support to helmet
1 Screw M5x35 2 ±20%
compartment fastener ( – )
Oil reservoir and cooling to frame Allen crowned-head
2 1.5 ±20%
fastener screw M5x16
Fuel sensor fastener 4 Nut M4 1 ±20%
Fuel valve to tank fastener ( ) 1 Tie 16 - 25 2 -
2 - 10
PERIODIC MAINTENANCE
SR 50
2 - 11
PERIODIC MAINTENANCE
SR 50
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, current measure is
cancelled and a new one is started.
If the MODE joystick is pressed after 10 seconds have
elapsed since chronometer start, current measure is
stopped, stored and a new one is started.
Hold down MODE joystick for a certain time to stop the
measurements.
It is possible to store up to 16 times in a row, that can be
displayed on the CHRONOMETER screen under the Menu
function (see “Menu Function”).
Menu function
Press the MODE joystick for a certain time to enter the
Menu. Press again the MODE joystick to access the
SETTINGS, CHRONOMETER, DIAGNOSTICS and
LANGUAGE sub-menus.
2 - 12
PERIODIC MAINTENANCE
SR 50
WARNING
To gain access to this area it is necessary to
enter the specific SERVICE CODE of this
vehicle.
The SERVICE CODE should never be disclosed
to the end user, it is intended for use by the
aprilia Authorised Dealers only.
2 - 13
PERIODIC MAINTENANCE
SR 50
INSTRUMENT PANEL
ERROR DESCRIPTION
ERROR CODE
Immobilizer failure: Key code read but not acknowledged DSB 01
Immobilizer failure: Key code not read (key not available or DSB 02
broken transponder)
Immobilizer failure: Broken antenna (open or short-circuited) DSB 03
Immobilizer failure: Inner controller failure DSB 04
Fuel sensor failure DSB 05
2 - 14
PERIODIC MAINTENANCE
SR 50
DELETE ERRORS: Select this function to delete the errors
detected by the ECU and the instrument panel.
WARNING
This operation is necessary before connecting
to the ECU with the AXONE or GAMEBOY, in
order to avoid disturbances in data
transmission across ECU and diagnosis
instrument.
2 - 15
PERIODIC MAINTENANCE
SR 50
CHANGE KEYS: The instrument panel manages the
immobilizer function through coded keys. In case the keys
are lost or the kill switch is changed, it is possible to code up
to 4 keys using this procedure.
WARNING
The user code stored on a new vehicle is
00000.
WARNING
The first key is the one already inserted, wait
for the key to be stored until the second key is
requested.
Proceed with the other keys or let the countdown get to zero
to end the operation.
2 - 16
PERIODIC MAINTENANCE
SR 50
RESTORE CODE: Should the user have forgotten the USER
CODE, it is possible to insert a new code through the
Restore Code function.
WARNING
This procedure irreversibly deletes the
previous User Code.
2 - 17
PERIODIC MAINTENANCE
SR 50
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). Hold down the Mode
button (2) for at least three seconds to reset stored trip
value.
Battery voltage.
With the odometer display, press the Mode button (2) twice
to display the battery function.
2 - 18
PERIODIC MAINTENANCE
SR 50
Check
CAUTION Place the vehicle on a firm and flat surface.
• Position the vehicle on the centre stand.
• Make sure that the fluid in the reservoir is above the
"MIN" level mark.
If the fluid does not reach at least the "MIN" mark, proceed
as follows:
WARNING
Brake fluid level decreases as the brake pads
wear down.
TOPPING UP
WARNING
Danger: brake fluid could leak out. Do not
operate the front brake lever if the screws are
loose or, most important, if the brake fluid
reservoir cover has been removed. Use a cloth
under the brake fluid reservoir.
2 - 19
PERIODIC MAINTENANCE
SR 50
WARNING
Avoid long 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 level.
WARNING
Never top up to maximum level, just top up
until level is above “MIN” mark. It is advisable
to top up until reaching the "MAX" level only
with new pads. Brake fluid level decreases as
the brake pads wear down. Do not reach the
"MAX" level with worn out pads, since this will
cause a fluid outflow when the pads are
changed.
2 - 20
PERIODIC MAINTENANCE
SR 50
CHECKING THE BRAKE PAD WEAR
CAUTION The following instructions apply to both brakes.
2 - 21
PERIODIC MAINTENANCE
SR 50
BLEEDING THE BRAKING SYSTEM
The air, if any, present inside the hydraulic circuit will serve
as "pad" by absorbing most of the pressure coming from the
brake master cylinder and thus reducing the calliper
efficiency during braking. If some air is present inside the
circuit, the brake control is "spongy" and the braking
efficiency is reduced.
DANGER
It is fundamental that air is bled off the
hydraulic circuit after the brakes have been
refitted and the braking system has been
restored to its standard operating conditions,
since it would be very dangerous for the
vehicle and the rider not to do so.
WARNING
Do not soil brake pads or disc with brake fluid.
WARNING
Tighten bleed valve before releasing the lever
in order to prevent air from getting in the brake
circuit.
2 - 22
PERIODIC MAINTENANCE
SR 50
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.
Do not clean the filtering element with petrol or
solvents, since they may cause a fire in the fuel
supply system, with serious danger for the
persons in the vicinity and for the vehicle.
• Change the air filter with a new one of the same type.
2 - 23
PERIODIC MAINTENANCE
SR 50
2.2.3. COOLANT
CHECKING AND TOPPING UP THE
COOLANT LEVEL
WARNING
Wait for the engine to cool down before
checking or topping up coolant level.
If not so:
• Loosen the filler plug (by turning it anticlockwise by two
turns), without removing it.
• Wait a few seconds in order to release any residual
pressure.
• Unscrew and remove the plug.
WARNING
Do not put additives or other substances into
the fluid.
WARNING
In case of excessive consumption of coolant
and in case the expansion reservoir remains
empty, make sure that there are no leaks in the
circuit.
2 - 24
PERIODIC MAINTENANCE
SR 50
2 - 25
PERIODIC MAINTENANCE
SR 50
Check
WARNING
Allow several minutes for the engine and
exhaust system to cool down.
TOPPING UP
2 - 26
PERIODIC MAINTENANCE
SR 50
CHANGE
WARNING
Allow several minutes for the engine and
exhaust system to cool down.
WARNING
Used oil contains substances that are very
dangerous for the environment. Dispose of
used oil in accordance with applicable
regulations.
2 - 27
PERIODIC MAINTENANCE
SR 50
WARNING
Allow several minutes for the engine and
exhaust system to cool down.
• Loosen and remove the filler plug (3) and oil drain plug
(2).
• Let oil fully drain off the crankcase.
• Measure the quantity, if it is less than 130 cu.cm (7.93
cu. in), restore correct level by topping up, see
(LUBRICANT CHART).
• Tighten the drain plug (2).
• Refill with oil recovered in the graduated container (1).
• 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.
Do not use the vehicle with insufficient
lubrication or with contaminated or unsuitable
lubricants, since this would cause early wear of
the moving parts and may also cause
irreparable failures.
CHANGE
2 - 28
PERIODIC MAINTENANCE
SR 50
• Loosen and remove the filler plug (3) and oil drain plug
(2).
• Let oil fully drain off the crankcase.
• Tighten the drain plug (2) and pour through the filler
130 cu. cm (7.93 cu. in) 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.
Do not use the vehicle with insufficient
lubrication or with contaminated or unsuitable
lubricants, since this would cause early wear of
the moving parts and may also cause
irreparable failures.
2 - 29
PERIODIC MAINTENANCE
SR 50
TOPPING UP
CAUTION The vehicle fits a separated mixer that mixes fuel
and oil, necessary for lubrication.
• Remove the front cover, see (REMOVING THE
FRONT COVER).
• Remove plug.
• Fill with oil, see (LUBRICANT CHART).
• Refit plug.
AIR BLEED
WARNING
Should oil in the mixer oil tank result used up
or if the mixer oil line is removed -from mixer to
reed assembly- it is necessary to bleed the
system. This operation is necessary because
engine might be damaged if running with air in
the mixer oil system.
2 - 30
PERIODIC MAINTENANCE
SR 50
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 plug.
• Fill with oil, see (LUBRICANT CHART)
• Refit plug.
AIR BLEED
CAUTION the vehicle fits a self-bleeding electronic pump.
Should oil in the mixer oil tank result used up or if the mixer
oil line is removed -from mixer to reed assembly- it is
necessary to bleed the system. Proceed as follows:
• Completely open the throttle grip.
• Keep the throttle open, turn the key to ON.
• You will hear the noise of the pump.
• Look at the mixer oil line going from the mixer to the
reed assembly and keep the throttle completely open
until the line is full of oil.
• Release of the throttle twistgrip.
• If necessary, top up with mixer oil as described above.
2 - 31
FUEL SYSTEM
SR 50
FUEL SYSTEM 3
3-1
FUEL SYSTEM
SR 50
SUMMARY
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. REMOVING THE FUEL TANK IE361 – IE50............................................................................................. 5
3.1.4. REMOVING THE FUEL TANK C364 ......................................................................................................... 7
3.1.5. REMOVING THE FUEL SENSOR............................................................................................................. 9
3.2. AIR FILTER..................................................................................................................................................... 10
3.2.1. REMOVING THE AIR FILTER AND THE AIR BOX IE361 - IE50............................................................ 10
3.2.2. REMOVING THE AIR FILTER AND THE AIR BOX C364 ....................................................................... 12
3.3. INJECTION UNIT............................................................................................................................................ 13
3.3.1. INJECTION SYSTEM DIAGRAM IE50 .................................................................................................... 13
3.3.2. REMOVING THE THROTTLE BODY IE361 – IE50 ................................................................................ 14
3.3.3. REMOVING THE INJECTION UNIT IE361 – IE50 .................................................................................. 15
3.4. CARBURETTOR............................................................................................................................................. 16
3.4.1. CARBURETTOR DIAGRAM C364 .......................................................................................................... 16
3.4.2. REMOVING THE CARBURETTOR C 364 .............................................................................................. 17
3-2
FUEL SYSTEM
SR 50
Key:
1. Fuel tank;
2. Fuel level sensor;
3. Fuel collection rubber element;
4. Three-way fitting;
5. Fuel filter;
6. Fuel pump;
7. Fuel tank-filter line;
8. Fuel filter-pump line;
9. “Overflow” line;
10. Fuel return hose;
11. Breather hose;
12. High-pressure fuel from injection unit;
13. Low-pressure fuel from injection unit.
3-3
FUEL SYSTEM
SR 50
Key:
1. Fuel tank;
2. Fuel level sensor;
3. Fuel collection rubber element;
4. “Overflow” line;
5. Breather hose;
6. Vacuum fuel cock;
7. Fuel hose;
8. Vacuum hose.
3-4
FUEL SYSTEM
SR 50
3-5
FUEL SYSTEM
SR 50
3-6
FUEL SYSTEM
SR 50
3-7
FUEL SYSTEM
SR 50
3-8
FUEL SYSTEM
SR 50
3-9
FUEL SYSTEM
SR 50
3 - 10
FUEL SYSTEM
SR 50
3 - 11
FUEL SYSTEM
SR 50
3.2.2. REMOVING THE AIR FILTER AND THE AIR BOX C364
REMOVING THE AIR FILTER C364
WARNING
Do not force during removal. The air box cover
(3) stays connected to the line (4).
3 - 12
FUEL SYSTEM
SR 50
Key:
1. Fuel tank
2. Fuel pump
3. Oil reservoir
4. Oil pump
5. ECU
6. Coil
7. Air intake
8. Air compressor
9. Throttle body
10. Pressure regulator
11. Fuel injector
12. Direct injector
3 - 13
FUEL SYSTEM
SR 50
3 - 14
FUEL SYSTEM
SR 50
3 - 15
FUEL SYSTEM
SR 50
3.4. CARBURETTOR
3.4.1. CARBURETTOR DIAGRAM C364
Key:
1. Throttle valve cover
2. Throttle valve spring
3. Maximum jet 53
4. Minimum jet 32
5. Complete float chamber
6. Float chamber drain screw
7. Throttle valve
8. Choke
9. Tapered needle
10. Fuel closing pin
11. Float chamber bleed line
12. Screw
13. Throttle valve adjuster
14. Float chamber securing screw
15. Screw
16. Ring
17. Complete float
18. Tapered needle housing
19. Air screw
20. Float pin
21. Idle speed air screw spring
22. Throttle valve adjuster spring
23. Plate
3 - 16
FUEL SYSTEM
SR 50
3 - 17
FUEL SYSTEM
SR 50
3 - 18
FUEL SYSTEM
SR 50
3 - 19
ENGINE
SR 50
ENGINE 4
4- 1
ENGINE
SR 50
SUMMARY
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................................................................................................................................................. 13
4.2.1. REMOVING THE ENGINE IE 50 ............................................................................................................. 13
4.2.2. INSTALLING THE ENGINE IE 50............................................................................................................ 17
4.3. ENGINE C 364................................................................................................................................................ 21
4.3.1. REMOVING THE ENGINE C 364............................................................................................................ 21
4.3.2. INSTALLING THE ENGINE C 364 .......................................................................................................... 26
4.4. SECONDARY AIR SYSTEM........................................................................................................................... 30
4.4.1. SECONDARY AIR SYSTEM ................................................................................................................... 30
4-2
ENGINE
SR 50
4- 3
ENGINE
SR 50
• Slide the two intake hoses out of the ties on the frame.
4-4
ENGINE
SR 50
• Open the tab and remove the mixer oil pump control
cable.
4- 5
ENGINE
SR 50
4-6
ENGINE
SR 50
4- 7
ENGINE
SR 50
4-8
ENGINE
SR 50
4- 9
ENGINE
SR 50
4 - 10
ENGINE
SR 50
WARNING
Before using the vehicle, bleed the mixer oil
pump, see (MIXER OIL IE361 - C364) and
(MIXER OIL IE50).
4- 11
ENGINE
SR 50
4 - 12
ENGINE
SR 50
4.2. ENGINE IE 50
4.2.1. 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.
4- 13
ENGINE
SR 50
• Slide the two intake hoses out of the ties on the frame.
4 - 14
ENGINE
SR 50
4- 15
ENGINE
SR 50
4 - 16
ENGINE
SR 50
4- 17
ENGINE
SR 50
4 - 18
ENGINE
SR 50
4- 19
ENGINE
SR 50
4 - 20
ENGINE
SR 50
4- 21
ENGINE
SR 50
4 - 22
ENGINE
SR 50
4- 23
ENGINE
SR 50
4 - 24
ENGINE
SR 50
4- 25
ENGINE
SR 50
4 - 26
ENGINE
SR 50
4- 27
ENGINE
SR 50
• Fit and tighten the two upper screws securing the lower
cover.
• Fit cover.
• Fit and tighten a new clamp.
4 - 28
ENGINE
SR 50
4- 29
ENGINE
SR 50
SYSTEM DIAGRAM
Key:
1. Intake manifold;
2. Secondary air valve;
3. From the engine;
4. Exhaust.
4 - 30
ENGINE
SR 50
SAS
DETAILS OF SAS
4- 31
ENGINE
SR 50
REMOVING AND CLEANING THE AIR FILTER
4 - 32
ENGINE
SR 50
4- 33
CYCLE PARTS
SR 50
CYCLE PARTS 5
5-1
CYCLE PARTS
SR 50
SUMMARY
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................................................................................................................. 5
5.1.4. REMOVING THE LOWER SHIELD ........................................................................................................... 7
5.1.5. REMOVING THE FRONT COVER ............................................................................................................ 8
5.1.6. REMOVING THE FRONT MUDGUARD.................................................................................................... 9
5.1.7. REMOVING THE REAR MUDGUARD .................................................................................................... 10
5.1.8. REMOVING THE TOOL KIT COMPARTMENT....................................................................................... 11
5.1.9. REMOVING THE INNER SHIELD ........................................................................................................... 12
5.1.10. REMOVING THE HEADLIGHT ............................................................................................................ 14
5.1.11. REMOVING THE FRONT WHEELHOUSE.......................................................................................... 16
5.1.12. REMOVING THE INSTRUMENT PANEL ............................................................................................ 17
5.2. EXHAUST SYSTEM ....................................................................................................................................... 19
5.2.1. REMOVING THE EXHAUST SYSTEM IE361 – C364............................................................................. 19
5.2.2. REMOVING THE EXHAUST SYSTEM IE50 ........................................................................................... 20
5.3. FRONT WHEEL.............................................................................................................................................. 21
5.3.1. FRONT WHEEL DIAGRAM ..................................................................................................................... 21
5.3.2. REMOVING THE FRONT WHEEL .......................................................................................................... 22
5.4. REAR WHEEL ................................................................................................................................................ 23
5.4.1. REAR WHEEL DIAGRAM ....................................................................................................................... 23
5.4.2. REMOVING THE REAR WHEEL ............................................................................................................ 24
5.5. BRAKING SYSTEM ........................................................................................................................................ 25
5.5.1. CHANGING THE BRAKE PADS ............................................................................................................. 25
5.6. STEERING...................................................................................................................................................... 27
5.6.1. STEERING DIAGRAM............................................................................................................................. 27
5.7. FRONT FORK................................................................................................................................................. 28
5.7.1. FRONT FORK DIAGRAM........................................................................................................................ 28
5.7.2. REMOVING THE FORK LEG .................................................................................................................. 29
5.7.3. DISASSEMBLING THE STANCHION ..................................................................................................... 30
5.8. REAR SUSPENSION ..................................................................................................................................... 31
5.8.1. REMOVING THE SHOCK ABSORBER................................................................................................... 31
5-2
CYCLE PARTS
SR 50
5-3
CYCLE PARTS
SR 50
5-4
CYCLE PARTS
SR 50
5-5
CYCLE PARTS
SR 50
5-6
CYCLE PARTS
SR 50
5-7
CYCLE PARTS
SR 50
5-8
CYCLE PARTS
SR 50
5-9
CYCLE PARTS
SR 50
5 - 10
CYCLE PARTS
SR 50
5 - 11
CYCLE PARTS
SR 50
5 - 12
CYCLE PARTS
SR 50
• 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.
5 - 13
CYCLE PARTS
SR 50
5 - 14
CYCLE PARTS
SR 50
5 - 15
CYCLE PARTS
SR 50
5 - 16
CYCLE PARTS
SR 50
WARNING
During reassembly, ensure to perfectly align
the connector with the instrument panel, to
avoid damaging the instrument panel pins.
5 - 17
CYCLE PARTS
SR 50
5 - 18
CYCLE PARTS
SR 50
5 - 19
CYCLE PARTS
SR 50
5 - 20
CYCLE PARTS
SR 50
Key:
5 - 21
CYCLE PARTS
SR 50
WARNING
Do not operate the front brake lever when the
wheel is not in place or the calliper piston
might come off its housing, thus causing brake
fluid leakage.
5 - 22
CYCLE PARTS
SR 50
Key:
1. Tyre
2. Bare rear wheel
3. Brake disc
4. Tubeless valve
5. Pads
6. Rear brake calliper
7. Air bleed
8. Rear brake line
9. Rear wheel nut
10. Rear wheel plate
11. Ring
12. Pin + calliper spring
13. Bare rear hub ( – )
14. Split pin
15. Cap
5 - 23
CYCLE PARTS
SR 50
• Remove cover.
WARNING
Do not operate the front brake lever when the
wheel is not in place or the calliper piston
might come off its housing, thus causing brake
fluid leakage.
5 - 24
CYCLE PARTS
SR 50
WARNING
Be careful not to damage the rim paint during
removal and reassembly of the calliper on the
disc.
While changing pads, protect the rim with tape.
5 - 25
CYCLE PARTS
SR 50
WARNING
Do not operate the brake lever when the pads
are not in place or the calliper piston might
come off its housing, thus causing brake fluid
leakage.
Always change both pads and ensure they are
correctly in place inside the calliper.
5 - 26
CYCLE PARTS
SR 50
5.6. STEERING
5.6.1. STEERING DIAGRAM
Key:
1. Dust seal
2. Lock nut
3. Adjuster nut
4. Upper bearing
5. Lower bearing
6. Steering
5 - 27
CYCLE PARTS
SR 50
Key:
1. Rubber cap
2. Snap ring
3. Fork clamp bolts
4. Snap ring
5. Sealing cap
6. O-ring
7. Rubber seal
8. Spring
9. Damping cylinder
10. Counter spring
11. Buffer
12. Left slider
13. Right slider
14. Dust seal
15. Snap ring
16. Seal
17. Left stanchion tube
18. Right stanchion tube
19. Securing screws
20. Sealing washer
21. Capscrew
5 - 28
CYCLE PARTS
SR 50
5 - 29
CYCLE PARTS
SR 50
WARNING
Check oil level. If lower than 103 cu. cm (6.28
cu.in.), top up or change.
WARNING
While reassembling, fit the circlip (9) with the
sharp edge fully home (see figure).
5 - 30
CYCLE PARTS
SR 50
WARNING
Fit a suitable shim in-between the frame and
the rear wheel, to avoid that the air box sinks
and pushes on the inspection cover.
5 - 31
COOLING SYSTEM
SR 50
COOLING SYSTEM 6
6-1
COOLING SYSTEM
SR 50
SUMMARY
6.1. COOLING SYSTEM.......................................................................................................................................... 3
6.1.1. DIAGRAM .................................................................................................................................................. 3
6.2. EMPTYING THE COOLING SYSTEM.............................................................................................................. 4
6.2.1. EMPTYING THE COOLING SYSTEM....................................................................................................... 4
6-2
COOLING SYSTEM
SR 50
Key:
6-3
COOLING SYSTEM
SR 50
6-4
ELECTRICAL SYSTEM
SR 50
ELECTRICAL SYSTEM 7
7-1
ELECTRICAL SYSTEM
SR 50
SUMMARY
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................................................................................................. 11
7.2. WIRING SYSTEM DIAGRAMS....................................................................................................................... 14
7.2.1. WIRING DIAGRAM IE 361 ...................................................................................................................... 14
7.2.2. WIRING DIAGRAM IE 50 ........................................................................................................................ 16
7.2.3. WIRING DIAGRAM C 364 ....................................................................................................................... 18
7-2
ELECTRICAL SYSTEM
SR 50
1 Generator:
three-phase generator
winding resistance: 1 ohm
output voltage 50AC (to be measured with generator
disconnected from wiring system and engine at 3000 rpm)
2 Rpm sensor:
inductive sensor
winding resistance: 110 ohm
7-3
ELECTRICAL SYSTEM
SR 50
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: 0.7 ohm
7-4
ELECTRICAL SYSTEM
SR 50
7 Fuel sensor:
resistance across terminals 1 and 3:
- 5 ohm with full fuel tank
- 38 ohm with half full fuel tank
- 100 ohm 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
- Fuel sensor
- Coolant temperature sensor
9 Charging voltage:
voltage 13.5 V ± 0.3 V to be measured at battery poles (with
engine at 3000 rpm)
10 Headlight:
low beam 12 V – 35 W
high beam 12 V – 35 W
7-5
ELECTRICAL SYSTEM
SR 50
11 Throttle body
FUEL INJECTOR
winding resistance: 1.7 ohm
12 Air injector:
winding resistance: 1.3 ohm
7-6
ELECTRICAL SYSTEM
SR 50
1 Generator:
three-phase generator
winding resistance: 1 ohm
output voltage 50AC (to be measured with generator
disconnected from wiring system and engine at 3000 rpm)
2 Rpm sensor:
inductive sensor
winding resistance: 110 ohm
7-7
ELECTRICAL SYSTEM
SR 50
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: 0.7 ohm
7-8
ELECTRICAL SYSTEM
SR 50
7 Fuel sensor:
resistance across terminals 1 and 3:
- 5 ohm with full fuel tank
- 38 ohm with half full fuel tank
- 100 ohm 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
- Direction indicators
- Mixer oil reserve sensor
- Fuel sensor
- Coolant temperature sensor
9 Charging voltage:
voltage 13.5 V ± 0.3 V to be measured at battery poles (with
engine at 3000 rpm)
10 Headlight:
low beam 12 V – 35 W
low/high beam 12 V – 35 W
7-9
ELECTRICAL SYSTEM
SR 50
11 Throttle body
FUEL INJECTOR
winding resistance: 1.7 ohm
12 Air injector:
winding resistance: 1.3 ohm
7 - 10
ELECTRICAL SYSTEM
SR 50
1 Generator:
two-phase generator
winding resistance: 0.5-1 ohm
output voltage 30-35 VAC (to be measured with generator
disconnected from wiring system and engine cranking)
2 Rpm sensor:
inductive sensor
winding resistance: 110 ohm
7 - 11
ELECTRICAL SYSTEM
SR 50
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 ohm with full fuel tank
- 100 ohm with empty fuel tank
- 38 ohm with half full fuel tank
6 Fuses:
7 - 12
ELECTRICAL SYSTEM
SR 50
7 Headlight:
low beam 12 V – 35 W
high beam 12 V – 35 W
7 - 13
ELECTRICAL SYSTEM
SR 50
7 - 14
ELECTRICAL SYSTEM
SR 50
Key:
1. Multiple connectors
2. Low-high beam relay
3. Oil level switch
4. Fuel level sensor
5. Instrument panel (matrix)
6. Immobilizer antenna
7. Key-operated switch
8. Warning horn
9. Left dimmer switch
10. Rear stop switch (on left dimmer switch)
11. Right dimmer switch
12. Front stop switch (on right dimmer switch)
13. Rear left turn indicator
14. Tail light
15. Parking light/brake light
16. Rear right turn indicator
17. Number plate light ( - only)
18. Pick-up sensor
19. Generator
20. Voltage regulator
21. Injection relay
22. Starter relay (noise proof)
23. Starter motor
24. Battery
25. Fuses
26. Fuel pump
27. Air injector
28. Fuel injector
29. Pressure sensor (or integrated in the control unit)
30. Head temperature sensor
31. H.T. coil
32. Spark plug
33. Throttle sensor
34. Serial connector (diagnosis)
35. Oil pump
36. ECU
37. Speed sensor
38. Front right direction indicator
39. Front parking lights ( - only)
40. Low beam
41. High beam
42. Front left direction indicator
43. Headlight
44. Diode
45. -
46. -
47. -
48. -
49. -
7 - 15
ELECTRICAL SYSTEM
SR 50
7 - 16
ELECTRICAL SYSTEM
SR 50
Key:
1. Multiple connectors
2. -
3. Oil level switch
4. Fuel level sensor
5. Instrument panel (matrix)
6. Immobilizer antenna
7. Key-operated switch
8. Warning horn
9. Left dimmer switch
10. Rear stop switch (on left dimmer switch)
11. Right dimmer switch
12. Front stop switch (on right dimmer switch)
13. Rear left turn indicator
14. Tail light
15. Parking light/brake light
16. Rear right turn indicator
17. Number plate light ( - only)
18. Generator
19. Voltage regulator
20. Injection relay
21. Starter relay
22. Starter motor
23. Battery
24. Fuse
25. Spark plug
26. H.T. coil
27. Fuel pump
28. Air injector
29. Fuel injector
30. Oil pump
31. Temperature sensor
32. Pick-up sensor
33. Throttle sensor
34. Serial connector (diagnosis)
35. Pressure sensor (or integrated in the control unit)
36. ECU
37. Speed sensor
38. Front right direction indicator
39. Front parking lights ( - only)
40. Low beam
41. High beam
42. Front left direction indicator
43. Headlight
44. Diode
45. -
46. -
47. -
48. -
49. -
CABLE COLOURS
Ar Orange
Az Light blue
B Blue
Bi White
G Yellow
Gr Grey
M Brown
N Black
R Red
V Green
Vi Violet
Ro Pink
7 - 17
ELECTRICAL SYSTEM
SR 50
7 - 18
ELECTRICAL SYSTEM
SR 50
Key:
1. Multiple connectors
2. Speed sensor
3. Fuel level sensor
4. Instrument panel (easy)
5. Head temperature sensor
6. Oil level switch
7. Key ignition switch
8. Warning horn
9. Left dimmer switch
10. Rear stop switch (on left dimmer switch)
11. Right dimmer switch
12. Front stop switch (on right dimmer switch)
13. Rear left turn indicator
14. Tail light
15. Parking light/brake light
16. Rear right turn indicator
17. Number plate light ( - only)
18. Starter relay
19. Starter motor
20. Battery
21. Fuses
22. Regulator
23. Pick-up sensor
24. Generator
25. SPARK PLUG
26. Transducer
27. Automatic choke
28. Front right direction indicator
29. Front parking lights ( - only)
30. Low beam
31. High beam
32. Front left direction indicator
33. Headlight
34. Serial connector (diagnosis)
35. -
36. -
37. -
38. -
7 - 19
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.com