Table Of Contents - APRILIA SR 50 Service And Repair Manual

SR 50
4!",% /& #/.4%.43
FOREWORD ...............................................................................7
Safety Warnings .................................................................7
General Safety Rules .......................................................7
Carbon Monoxide ..................................................................7
GASOLINE ...................................................................................7
Hot Components....................................................................7
Used Engine Oil ......................................................................8
BRAKE FLUID ..............................................................................8
Coolant ....................................................................................8
Battery HYDROGEN GAS AND ELECTROLYTE ...................8
Precautions And General InformationS.....................8
HOW TO USE
YOUR SERVICE AND REPAIR MANUAL ..................................9
ELECTRICAL CONNECTORS ...................................................11
GENERAL SPECIFICATIONS
OF THE DRIVING TORQUES ....................................................11
Technical Data ..................................................................15
Driving Torque ...................................................................17
Lubricant Chart ................................................................19
Troubleshooting ..............................................................26
REGULAR SERVICE INTERVALS CHART ..............................29
Identification Data ...........................................................31
Arrangement Of The Main Elements ..........................31
Arrangement Of The Instruments ..............................33
Instruments And Indicators .........................................33
CHECKING THE OPERATION
OF THE ACCELERATOR CONTROL .......................................33
Idling Adjustment .............................................................35
Adjusting The Accelerator Control ........................37
Fairings .................................................................................39
Removing The Passenger Grab Handle .....................39
REMOVING THE NUMBER PLATE-HOLDER ..........................39
REMOVING THE LOWER GUARD
OF THE REAR PART OF THE FAIRING ..................................39
Removing The Rear Part Of The Fairing ....................39
Removing The Right And Left Inspection Covers ..41
Removing The Lower Shield Cover .............................41
Removing The Front Inner Shield ................................43
Removing The Front Cover ............................................43
Removing The Footboard ...............................................45
Removing The Front Mudguard ....................................45
Removing The Rear-View Mirrors ................................47
Removing The Handlebar Cover ..................................47
Removing The Crash Helmet Compartment
complete with saddle .................................................................49
Removing The Front Shield Cover ..............................49
Removing The Rear Mudguard ......................................51
REMOVING THE COVER
OF THE REAR PART OF THE FAIRING ..................................51
Removing The Front Outer Shield ..............................53
Removing The Lower Shield ...........................................53
Fuel Tank .............................................................................55
Fuel ........................................................................................55
Checking The Vacuum Tap ...............................................57
Draining The Fuel Tank ....................................................57
Removing The Vacuum Tap ..............................................59
CHECKING THE FUEL LEVEL GAUGE UNIT ..........................61
Removing The Fuel Level Gauge Unit ..........................61
Removing The Complete Fuel Tank ..............................61
2 STROKE OIL TANK ..............................................................63
CHECKING ...............................................................................63
DRAINING ................................................................................63
REMOVAL ................................................................................63
Bleeding The 2 Stroke Oil Tank ....................................65
1
Cooling System ..........................................................67
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COOLANT .........................................................................67
CHECKING THE COOLANT LEVEL
1
AND TOPPING UP ............................................................69
Draining The Coolant System ......................................71
Changing The Coolant ....................................................73
Bleeding The Coolant System
Removing The Radiator
Removing The Coolant Pump
Removing The Expansion Tank
REMOVING
THE COOLANT TEMPERATURE TERMISTOR
Bulbs .....................................................................................81
Headlight Bulbs ................................................................81
Adjusting The Vertical Headlight Beam ...................81
Horizontal Adjustment Of The Headlight Beam
(for the countries where required) ..............................................83
Changing The Headlight Bulbs .....................................85
CHANGING THE HEADLIGHT BULBS
Removing The Headlight .................................................87
1
...............................75
1
............................................77
1
1 ..................................77
...............................79
1
................79
C % - _
........85
FRONT DIRECTION INDICATOR ............................................ 87
CHANGING THE BULBS ......................................................... 87
REMOVING THE WHOLE INDICATOR ................................... 87
REAR DIRECTION INDICATOR .............................................. 89
CHANGING THE BULBS ......................................................... 89
REMOVING THE COMPLETE DIRECTION INDICATOR ......... 89
REAR LIGHT ........................................................................... 91
CHANGING THE BULBS ......................................................... 91
REMOVING THE REAR LIGHT ............................................... 91
CHANGING
THE NUMBER PLATE BULB
DASHBOARD .......................................................................... 93
CHANGING THE BULBS ......................................................... 93
Removing The Complete Dashboard .......................... 95
Removing The Dashboard Glass .................................. 95
Electric Control Supports ........................................ 95
Removing The Handlebar Controls ........................... 95
BRAKE FLUID - recommendations ....................................... 97
DISC BRAKES ...................................................................... 101
CHECKING ............................................................................ 101
TOPPING UP ......................................................................... 103
3
REAR DRUM BRAKE
ADJUSTING THE BRAKE ...................................................... 105
FRONT WHEEL ..................................................................... 107
DISASSEMBLY ...................................................................... 107
CHECKING ............................................................................ 107
REASSEMBLY ....................................................................... 109
REAR WHEEL ....................................................................... 111
DISASSEMBLY ...................................................................... 111
GREASING THE REAR BRAKE CAM PIN
BRAKE CALIPERS ............................................................... 115
Removing The Front Brake Caliper .......................... 115
Removing The Rear Brake Caliper ............................ 117
BRAKE PADS ....................................................................... 119
Checking Wear Of The Brake Pads ........................... 119
Changing The Brake Pads ............................................ 119
Bleeding The Braking System .................................... 121
3
Brake Shoes .............................................................. 123
Checking The Shoe Wear
Changing The Shoes
Transmission .................................................................... 125
Checking The Transmission Oil Level ...................... 125
Changing The Transmission Oil ................................. 127
Checking The Engine Fulcrum Axis .......................... 129
WHEELS / TYRES ................................................................. 129
Inspecting The Wheels ................................................. 129
Tyres ................................................................................... 131
Tyre Pressure ................................................................. 133
Steering Tube .................................................................. 135
Checking The Bearing Slack ....................................... 135
Adjusting The Bearing Slack ..................................... 135
Removing The Steering Tube Bearings ................... 137
FRONT FORK ........................................................................ 139
CHECKING THE FORK OIL LEVEL ....................................... 139
REMOVING THE COMPLETE FORK ..................................... 139
REMOVING
THE TUBE/WHEEL-HOLDER UNIT (with installed fork) ......... 141
Disassembling The Tube/Wheel-Holder .................. 141
REAR SUSPENSION ............................................................. 143
REMOVAL ............................................................................. 143
EXHAUST SILENCER ........................................................... 143
DISASSEMBLY ...................................................................... 143
AIR CLEANER ....................................................................... 145
REMOVAL ............................................................................. 145
Cleaning The Air Filter ................................................. 145
IGNITION SWITCH / STEERING LOCK ................................ 145
REMOVAL ............................................................................. 145
Battery .............................................................................. 147
Checking The Electrolyte Level .............................. 149
Recharging The Battery .............................................. 149
Long Inactivity Of The Battery ................................. 151
ENGINE ................................................................................. 153
Removing The Engine From The Frame ..................... 153
1
ENGINE (liquid-cooled version) ................................... 157
REMOVING THE ENGINE FROM THE FRAME .................... 157
ENGINE CONNECTION LINK ............................................... 159
REMOVAL ............................................................................. 159
Electrical System ......................................................... 163
CONTENTS ........................................................................... 163
14
A C % - _
............... 93
..................................................... 105
3
.................. 113
3
....................................... 123
3
............................................... 123