APRILIA SR 50 Workshop Manual
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APRILIA SR 50 Workshop Manual

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SR 50
1228 4
00/2004-10
workshopmanual
WWW.PlanDeGraissage.ORG

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Summary of Contents for APRILIA SR 50

  • Page 1 SR 50 1228 4 00/2004-10 workshopmanual WWW.PlanDeGraissage.ORG...
  • Page 2 INTRODUCTION SR 50 INTRODUCTION 0 - 1 WWW.PlanDeGraissage.ORG...
  • Page 3 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 WWW.PlanDeGraissage.ORG...
  • Page 4 manual.
  • Page 5 INTRODUCTION SR 50 0.1.2. REFERENCE MANUALS SPARE PARTS CATALOGUES Version aprilia part# (description) 5564_00 Version aprilia part# (description) 5574_00 OWNER'S MANUALS aprilia part# 8202397 8202441 8202442 8202439 ENGINE WORKSHOP MANUAL Engines aprilia part# 8140818 8140821 8140819 8140820 8140822 8CM0067 ENGINE WORKSHOP MANUAL...
  • Page 6 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 ±...
  • Page 7 INTRODUCTION SR 50 TEST = diagnostic check T.B.E.I. = crown-head Allen screw T.C.E.I. = cheese-head Allen screw T.E. = hexagonal head T.P. = flat head screw = Twin Spark Ignition UPSIDE-DOWN = inverted fork = volt = watt 0 - 6...
  • Page 8 GENERAL INFORMATION SR 50 GENERAL INFORMATION 1 - 1 WWW.PlanDeGraissage.ORG...

  • Page 9: Table Of Contents

    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.

  • Page 10: Structure Of The Manual

    GENERAL INFORMATION SR 50 1.1. STRUCTURE OF THE MANUAL 1.1.1. CONVENTIONS USED IN THE MANUAL • This manual is divided in sections and subsections, each covering a set of the most significant components. Refer to the index of sections when consulting the manual.

  • Page 11: Safety Warnings

    GENERAL INFORMATION SR 50 1.1.2. SAFETY WARNINGS The following precautionary warnings are used throughout this manual in order to convey the following messages: Safety warning. This symbol appears, whether in the manual or on the vehicle itself, to indicate a personal injury hazard.

  • Page 12: General Rules

    GENERAL INFORMATION SR 50 1.2. GENERAL RULES 1.2.1. BASIC SAFETY RULES CARBON MONOXIDE Should it be necessary to perform some operations with the vehicle running, make sure to work outdoors or in a well- aerated room. Avoid starting the engine indoors.
  • Page 13 GENERAL INFORMATION SR 50 HYDROGEN AND BATTERY FLUID 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.
  • Page 14 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.

  • Page 15: Dangerous Elements

    GENERAL INFORMATION SR 50 1.3. DANGEROUS ELEMENTS 1.3.1. WARNINGS 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.
  • Page 16 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.
  • Page 17 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.

  • Page 18: Running-In

    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.

  • Page 19: Vehicle Identification

    GENERAL INFORMATION SR 50 1.5. VEHICLE IDENTIFICATION 1.5.1. POSITION OF THE SERIAL NUMBERS CAUTION Altering the vehicle identification numbers is a legal offence. Altering the frame number invalidates the warranty. FRAME NUMBER The frame number (1) is stamped on the frame central tube.
  • Page 20 PERIODIC MAINTENANCE SR 50 PERIODIC MAINTENANCE 2 - 1 WWW.PlanDeGraissage.ORG...
  • Page 21 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 MULTIFUNCTION DIGITAL COMPUTER C 364..................

  • Page 22: Specifications

    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.)
  • Page 23 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.

  • Page 24: Scheduled Maintenance Chart

    PERIODIC MAINTENANCE SR 50 2.1.2. SCHEDULED MAINTENANCE CHART Every 4000 km Every 8000 km After running-in Component (2500 mi) or 12 (5000 mi) or 24 [500 km (312 mi)] months months Rear shock absorber Battery - Electrolyte level SPARK PLUG Carburettor –...

  • Page 25: Lubricant Table

    PERIODIC MAINTENANCE SR 50 2.1.3. LUBRICANT TABLE LUBRICANT PRODUCT Gearbox oil RECOMMENDED: F.C., SAE 75W 90 or GEAR SYNTH, SAE 75W - As an alternative to recommended oil, top brand oils meeting or exceeding A.P.I. GL-4 specifications can be used.

  • Page 26: Tightening Torque Settings

    PERIODIC MAINTENANCE SR 50 2.1.4. TIGHTENING TORQUE SETTINGS 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...
  • Page 27 PERIODIC MAINTENANCE SR 50 Torque Description Q.ty Type of fastener Tol. Note (Nm) Exhaust Muffler flange to cylinder fastener Nut M6 ±20% Protection fastener onto muffler Screw M6x16 ±20% Muffler and mudguard to engine Screw M8x85 ±10% fastener Muffler fastener onto engine Screw M8x85 ±10%...
  • Page 28 PERIODIC MAINTENANCE SR 50 Torque Description Q.ty Type of fastener Tol. Note (Nm) Centre bodywork Passenger footboard platform to frame Allen crowned-head ±20% fastener screw M5x16 Allen crowned-head Under-platform to platform fastener ±20% screw M5x16 Self-tapping 4.2x16 Under-platform to platform fastener...
  • Page 29 PERIODIC MAINTENANCE SR 50 Torque Description Q.ty Type of fastener Tol. Note (Nm) Instrument panel / Steering head Instrument panel to support plate Self-tapping 5x14 plastic fastener Allen crowned-head Steering head to handlebar fastener ±20% screw M4x16 Self-tapping 3.9x14 Steering head to handlebar fastener...

  • Page 30: Multifunction Digital Computer Ie 361 - Ie 50

    PERIODIC MAINTENANCE SR 50 2.1.5. MULTIFUNCTION DIGITAL COMPUTER IE 361 – IE 50 Using the MODE joystick Using the MODE joystick on handlebar right side, it is possible to choose various functions in sequence; move the MODE joystick to the right or to the left (UP/DOWN) to scroll the functions, select the function by pressing rapidly, confirm data by pressing for a longer period.
  • Page 31 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.
  • Page 32 The SERVICE CODE should never be disclosed to the end user, it is intended for use by the aprilia Authorised Dealers only. Using the MODE joystick, enter the vehicle SERVICE CODE: 45256. You gain access to the diagnostics menu: ECU ERRORS: This menu allows you to display any current errors (active) or stored (memo) as detected by the ECU.
  • Page 33 PERIODIC MAINTENANCE SR 50 ERROR DESCRIPTION ECU ERROR CODE ECU 01 Engine overheat ECU 02 Pick-up sensor failure ECU 03 Wrong signal from throttle position sensors ECU 04 Wrong signal from throttle position sensor 1 ECU 05 Wrong signal from throttle position sensor 2...
  • Page 34 PERIODIC MAINTENANCE SR 50 DELETE ERRORS: Select this function to delete the errors detected by the ECU and the instrument panel. RESET SERVICE: Select this function to reset the SERVICE warning after the necessary maintenance has been carried out. DISCONNECT: Select this function to cut the instrument panel- ECU connection.
  • Page 35 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.
  • Page 36 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 previous User Code. KM/MILES: use this function to select the unit of measurement for the Tachometer / Odometer.

  • Page 37: Multifunction Digital Computer C 364

    PERIODIC MAINTENANCE SR 50 2.1.6. MULTIFUNCTION DIGITAL COMPUTER C 364 Multifunction indicator functions Use the Mode button (2), on handlebar left side, to select among various functions: clock setting, odometer (ODO), trip meter (TRIP), battery voltage value and trip meter reset.

  • Page 38: Scheduled Maintenance

    PERIODIC MAINTENANCE SR 50 2.2. SCHEDULED MAINTENANCE 2.2.1. BRAKING SYSTEM WARNING In case of excessive stroke of the brake lever, excessive elasticity or air bubbles, bleed the air out of the circuit. Do not use or mix different types of silicone or oil fluids.
  • Page 39 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. • Raise and remove cover (1).
  • Page 40 PERIODIC MAINTENANCE SR 50 CHECKING THE BRAKE PAD WEAR CAUTION The following instructions apply to both brakes. Outlined below is a quick brake pad inspection procedure: • Position the vehicle on the centre stand. • Using a lamp and a mirror located in-between brake...
  • Page 41 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"...

  • Page 42: Cleaning The Air Filter

    PERIODIC MAINTENANCE SR 50 2.2.2. CLEANING THE AIR FILTER • Remove the air filter, see (REMOVING THE AIR FILTER). • Wash the filtering element with clean, non-inflammable solvents or solvents with high volatility point, then let it dry thoroughly. •...

  • Page 43: Coolant

    PERIODIC MAINTENANCE SR 50 2.2.3. COOLANT CHECKING TOPPING COOLANT LEVEL WARNING Wait for the engine to cool down before checking or topping up coolant level. • Stop the engine and wait until it has cooled down. CAUTION Place the vehicle on a firm and flat surface.
  • Page 44 PERIODIC MAINTENANCE SR 50 • Start the vehicle and let it warm up. • Bleed again and top up. 2 - 25 WWW.PlanDeGraissage.ORG...

  • Page 45: Gear Fluid Ie361 - C364

    PERIODIC MAINTENANCE SR 50 2.2.4. GEAR FLUID IE361 – C364 CAUTION Use the recommended oil only, see (LUBRICANT CHART). • Ride until covering several kilometres to warm up engine up to operating temperature and then stop the engine. Check •...
  • Page 46 PERIODIC MAINTENANCE SR 50 CHANGE • Position the vehicle on firm and flat ground. • Position the vehicle on the centre stand. WARNING Allow several minutes for the engine and exhaust system to cool down. • Stop the engine and let it cool down, in order to allow the oil to flow into the crankcase and to cool down.

  • Page 47: Gear Fluid Ie50

    PERIODIC MAINTENANCE SR 50 2.2.5. GEAR FLUID IE50 CAUTION Use the recommended oil only, see (LUBRICANT CHART). CHECK • Ride until covering several kilometres to warm up engine up to operating temperature and then stop the engine. • Position the vehicle on firm and flat ground.
  • Page 48 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).

  • Page 49: Mixer Oil Ie361 - C364

    PERIODIC MAINTENANCE SR 50 2.2.6. MIXER OIL IE361 – C364 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.

  • Page 50: Mixer Oil Ie50

    PERIODIC MAINTENANCE SR 50 2.2.7. MIXER OIL IE50 TOPPING UP CAUTION The vehicle fits a control unit that manages an electronic pump controlling the correct quantity of oil for engine lubrication. • Remove the front cover, see (REMOVING THE FRONT COVER).
  • Page 51 FUEL SYSTEM SR 50 FUEL SYSTEM 3 - 1 WWW.PlanDeGraissage.ORG...
  • Page 52 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.

  • Page 53: Fuel Tank

    FUEL SYSTEM SR 50 3.1. FUEL TANK 3.1.1. FUEL FEED SYSTEM DIAGRAM IE361 – IE50 Key: Fuel tank; Fuel level sensor; Fuel collection rubber element; Three-way fitting; Fuel filter; Fuel pump; Fuel tank-filter line; Fuel filter-pump line; “Overflow” line; 10. Fuel return hose;...

  • Page 54: Fuel Supply System Diagram C364

    FUEL SYSTEM SR 50 3.1.2. FUEL SUPPLY SYSTEM DIAGRAM C364 Key: Fuel tank; Fuel level sensor; Fuel collection rubber element; “Overflow” line; Breather hose; Vacuum fuel cock; Fuel hose; Vacuum hose. 3 - 4 WWW.PlanDeGraissage.ORG...

  • Page 55: Removing The Fuel Tank Ie361 - Ie50

    FUEL SYSTEM SR 50 3.1.3. REMOVING THE FUEL TANK IE361 – IE50 • Remove the tool kit compartment, see (REMOVING THE TOOL KIT COMPARTMENT). • Remove the tail guard, see (REMOVING THE TAIL GUARD). • Disconnect the fuel sensor connector.
  • Page 56 FUEL SYSTEM SR 50 • Loosen and remove the two screws, collect the spacers. • Release the seat release cable on the tank end. • Remove fuel tank together with helmet compartment. 3 - 6 WWW.PlanDeGraissage.ORG...

  • Page 57: Removing The Fuel Tank C364

    FUEL SYSTEM SR 50 3.1.4. REMOVING THE FUEL TANK C364 • Remove the tool kit compartment, see (REMOVING THE TOOL KIT COMPARTMENT). • Remove the tail guard, see (REMOVING THE TAIL GUARD). • Disconnect the fuel sensor connector. • Release and remove the two screws.
  • Page 58 FUEL SYSTEM SR 50 • Release and remove the two screws. • Release the seat release cable on the tank end. • Remove fuel tank together with helmet compartment. 3 - 8 WWW.PlanDeGraissage.ORG...

  • Page 59: Removing The Fuel Sensor

    FUEL SYSTEM SR 50 3.1.5. REMOVING THE FUEL SENSOR • Raise the seat. • Remove cover. • Disconnect the connector. • Release the sensor and hook it with a suitable tool, turn it anticlockwise. • Remove the fuel sensor. 3 - 9...

  • Page 60: Air Filter

    FUEL SYSTEM SR 50 3.2. AIR FILTER 3.2.1. REMOVING THE AIR FILTER AND THE AIR BOX IE361 - IE50 REMOVING THE AIR FILTER IE 361 - IE 50 • Release and remove the three screws. • Loosen and remove the two screws, collect the washers and the spacers.
  • Page 61 FUEL SYSTEM SR 50 • Remove the air filter. REMOVING THE AIR BOX IE 361 - IE 50 • Loosen and remove the two screws, collect the washers and the spacers. • Loosen and remove the rear mudguard screw. •...

  • Page 62: Removing The Air Filter And The Air Box C364

    FUEL SYSTEM SR 50 3.2.2. REMOVING THE AIR FILTER AND THE AIR BOX C364 REMOVING THE AIR FILTER C364 • Loosen and remove the three screws (1). • Loosen and remove the two screws (2), collect the washers. WARNING Do not force during removal. The air box cover (3) stays connected to the line (4).

  • Page 63: Injection Unit

    FUEL SYSTEM SR 50 3.3. INJECTION UNIT 3.3.1. INJECTION SYSTEM DIAGRAM IE50 Key: Fuel tank Fuel pump Oil reservoir Oil pump Coil Air intake Air compressor Throttle body 10. Pressure regulator 11. Fuel injector 12. Direct injector 3 - 13...

  • Page 64: Removing The Throttle Body Ie361 - Ie50

    FUEL SYSTEM SR 50 3.3.2. REMOVING THE THROTTLE BODY IE361 – IE50 • Loosen the clamp and remove the throttle body intake manifold from the air box end. • Disconnect the connector. • Loosen the clamp. • Remove the throttle body from the right side of the vehicle, keep it attached to the throttle cable.

  • Page 65: Removing The Injection Unit Ie361 - Ie50

    FUEL SYSTEM SR 50 3.3.3. REMOVING THE INJECTION UNIT IE361 – IE50 • Move the fuel tank aside, keep it connected to the seat release cable fuel pump wiring, (REMOVING THE FUEL TANK). • Disconnect the fuel injector connector. •...

  • Page 66: Carburettor

    FUEL SYSTEM SR 50 3.4. CARBURETTOR 3.4.1. CARBURETTOR DIAGRAM C364 Key: Throttle valve cover Throttle valve spring Maximum jet 53 Minimum jet 32 Complete float chamber Float chamber drain screw Throttle valve Choke Tapered needle 10. Fuel closing pin 11. Float chamber bleed line 12.

  • Page 67: Removing The Carburettor C 364

    FUEL SYSTEM SR 50 3.4.2. REMOVING THE CARBURETTOR C 364 • Release and remove the two screws. • Unscrew and remove the screw. • Loosen the carburettor clamp. • Remove the air box. 3 - 17 WWW.PlanDeGraissage.ORG...
  • Page 68 FUEL SYSTEM SR 50 • Disconnect the automatic choke connector. • Pinch the two heater hoses. • Remove the two clamps and remove the hoses. • Pinch the fuel hose. • Remove the tie and disconnect the fuel hose. •...
  • Page 69 FUEL SYSTEM SR 50 • Remove the tie and disconnect the vacuum hose. • Loosen the tie and remove the carburettor from the intake manifold. • Loosen and remove the screw and remove the throttle cable with gate. 3 - 19...
  • Page 70 ENGINE SR 50 ENGINE 4- 1 WWW.PlanDeGraissage.ORG...
  • Page 71 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.
  • Page 72 ENGINE SR 50 4.1. ENGINE IE 361 4.1.1. REMOVING THE ENGINE IE 361 • To remove the crankcase, first remove the lower shield, the battery, the fuel tank, the throttle body, keep it connected to the throttle cable and drain the cooling system.
  • Page 73 ENGINE SR 50 • Slide the two intake hoses out of the ties on the frame. CAUTION Place some paper under the coupling to collect any oil spillage. • Disconnect the two mixer oil hoses • Fold the lines and tie them.
  • Page 74 ENGINE SR 50 • Remove the rubber plug. • Open the tab and remove the mixer oil pump control cable. • Disconnect the fuel injector connector. • Disconnect the engine temperature sensor connector. 4- 5 WWW.PlanDeGraissage.ORG...
  • Page 75 ENGINE SR 50 • Disconnect the compressed air injector connector. • Loosen the screw and remove the two ground cables. • Disconnect the starter motor positive cable from the relay end. • Remove the clamp. 4 - 6 WWW.PlanDeGraissage.ORG...
  • Page 76 ENGINE SR 50 • Working on the right side, loosen and remove the nut. • Working on the left side, remove the pin. • Remove the engine. 4- 7 WWW.PlanDeGraissage.ORG...
  • Page 77 ENGINE SR 50 4.1.2. INSTALLING THE ENGINE IE 361 • Move the frame in small motions until the holes match perfectly. • Working on the left side, fit the pin. • Working on the right side, tighten the nut. •...
  • Page 78 ENGINE SR 50 • Connect the connector to the compressed air injector. • Connect the engine temperature sensor connector. • Connect the connector to the fuel injector. • Clamp the wiring with a new tie. 4- 9 WWW.PlanDeGraissage.ORG...
  • Page 79 ENGINE SR 50 • Reposition the mixer oil pump cable in its housing and close the tab. CAUTION it might be necessary to adjust the mixer oil pump by making the two marks match. • Fit the spark plug cap.
  • Page 80 ENGINE SR 50 • Connect the generator connector. • Fit the cooling system hose to the coolant pump. • Clamp the hose with the tie. • Fill and bleed air off the cooling system. • Connect the two mixer oil hoses...
  • Page 81 ENGINE SR 50 • Set the rear brake calliper in place. • Tighten the two screws. • Reposition the two cable guides of the rear brake fluid hose. • Tighten the two screws. • Tighten the shock absorber top screw.
  • Page 82 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.
  • Page 83 ENGINE SR 50 • Slide the two intake hoses out of the ties on the frame. CAUTION Place some paper under the coupling to collect any oil spillage. • Disconnect the mixer oil hose • Fold the lines and tie them.
  • Page 84 ENGINE SR 50 • Disconnect the fuel injector connector. • Disconnect the engine temperature sensor connector. • Disconnect the compressed air injector connector. • Working on the left side, loosen the screw and remove the ground cable. 4- 15 WWW.PlanDeGraissage.ORG...
  • Page 85 ENGINE SR 50 • Disconnect the starter motor positive cable connector and remove the tie. • Disconnect the two wiring. • Working on the left side, loosen and remove the nut. • Working on the right side, remove the pin.
  • Page 86 ENGINE SR 50 4.2.2. INSTALLING THE ENGINE IE 50 • Move the frame in small motions until the holes match perfectly. • Working on the right side, fit the pin. • Working on the left side, tighten the nut. •...
  • Page 87 ENGINE SR 50 • Position the ground cable and tighten the screw. • Connect the connector to the compressed air injector. • Connect the engine temperature sensor connector. • Connect the connector to the fuel injector. 4 - 18 WWW.PlanDeGraissage.ORG...
  • Page 88 ENGINE SR 50 • Fit the spark plug cap. • Position the cooling system hose onto the head. • Tighten the clamp. • Connect the mixer oil hose • Place the two intake hoses on the frame. 4- 19 WWW.PlanDeGraissage.ORG...
  • Page 89 ENGINE SR 50 • Set the rear brake calliper in place. • Tighten the two screws. • Reposition the two cable guides of the rear brake fluid hose. • Tighten the two screws. • Tighten the shock absorber top screw.
  • Page 90 ENGINE SR 50 4.3. ENGINE C 364 4.3.1. REMOVING THE ENGINE C 364 • Remove the air box hose. • Remove the brake calliper, see (REMOVING THE BRAKE CALLIPER). • Loosen and remove the fifteen screws and remove the converter cover.
  • Page 91 ENGINE SR 50 • Remove the carburettor, see (REMOVING THE CARBURETTOR). • Remove the spark plug cap. • Disconnect the temperature sensor connector. • Remove the two rear side panels, see (REMOVING THE REAR SIDE PANELS). • Remove exhaust, (REMOVING EXHAUST).
  • Page 92 ENGINE SR 50 • Loosen and remove the two upper screws securing the lower cover. • Release and remove the lower screw of the lower cover. • Slide down the lower protection. • Loosen and remove the screw and remove the starter motor ground cables •...
  • Page 93 ENGINE SR 50 • Disconnect the connector. • Unscrew and remove the drain screw of the cooling system and drain it. • Loosen the clamp and remove the hose on the thermostatic valve end. • Using a belt and a suitable tool, lift the vehicle rear end.
  • Page 94 ENGINE SR 50 • Working on the opposite side, remove the pin. • Remove the engine. 4- 25 WWW.PlanDeGraissage.ORG...
  • Page 95 ENGINE SR 50 4.3.2. INSTALLING THE ENGINE C 364 • Move the frame in small motions until the holes match perfectly. • Insert the pin. • Working on the right side, fit and tighten the nut. • Fit the hose in the thermostatic valve.
  • Page 96 ENGINE SR 50 • Connect the connector. • Fit a new clamp to the wiring. • Position the starter motor ground cables. • Fit and tighten the screw. • Fit the lower protection. • Fit and tighten the lower screw of the lower cover.
  • Page 97 ENGINE SR 50 • Fit and tighten the two upper screws securing the lower cover. • Fit cover. • Fit and tighten a new clamp. • Fit and tighten the four screws. • Connect the alternator connector. 4 - 28...
  • Page 98 ENGINE SR 50 • Connect the temperature sensor. • Fit the spark plug cap. • Install the exhaust. • Install the two rear side panels. • Install the carburettor. • Fit the hose to the mixer oil pump. • Fit the clamp.
  • Page 99 ENGINE SR 50 4.4. SECONDARY AIR SYSTEM 4.4.1. SECONDARY AIR SYSTEM SYSTEM DIAGRAM Key: Intake manifold; Secondary air valve; From the engine; Exhaust. 4 - 30 WWW.PlanDeGraissage.ORG...
  • Page 100 ENGINE SR 50 The Secondary Air System (SAS) has been developed to reduce carbon oxide and unburnt hydrocarbon emissions in vehicles that are not equipped with a lambda sensor. Natural air (which is rich in oxygen) is channelled into the exhaust...
  • Page 101 ENGINE SR 50 REMOVING AND CLEANING THE AIR FILTER • Loosen the two screws and remove the aluminium cover of the system. • Remove the plastic cover and the filter. • Remove the single-acting valve housing, check the valve condition and refit them in their housings.
  • Page 102 ENGINE SR 50 4- 33 WWW.PlanDeGraissage.ORG...
  • Page 103 CYCLE PARTS SR 50 CYCLE PARTS 5 - 1 WWW.PlanDeGraissage.ORG...
  • Page 104 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.

  • Page 105: Outer Structures

    CYCLE PARTS SR 50 5.1. OUTER STRUCTURES 5.1.1. REMOVING THE SEAT • Remove the central inspection cover. • Slide out the split pin. • Raise the seat. • Remove pin. • Remove the seat. 5 - 3 WWW.PlanDeGraissage.ORG...

  • Page 106: Removing The Passenger Grab Handle

    CYCLE PARTS SR 50 5.1.2. REMOVING THE PASSENGER GRAB HANDLE • Raise the seat. • Release and remove the four screws. • Remove the passenger grab handle. 5 - 4 WWW.PlanDeGraissage.ORG...

  • Page 107: Removing The Tail Guard

    CYCLE PARTS SR 50 5.1.3. REMOVING THE TAIL GUARD • Remove the passenger grab handle, see (REMOVING THE PASSENGER GRAB HANDLE). • Working on either side, loosen and remove the two side screws. • Release and remove the fourteen top screws.
  • Page 108 CYCLE PARTS SR 50 • Disconnect the tail light connector. • Remove the tail guard together with number plate holder. 5 - 6 WWW.PlanDeGraissage.ORG...

  • Page 109: Removing The Lower Shield

    CYCLE PARTS SR 50 5.1.4. REMOVING THE LOWER SHIELD • Release and remove the three front screws. • Working on either side, loosen and remove the rear screw. • Release and remove the three top screws. • Remove the lower shield.

  • Page 110: Removing The Front Cover

    CYCLE PARTS SR 50 5.1.5. REMOVING THE FRONT COVER • Release and remove the two outer screws. • Lift the front cover just enough to release it. • Remove the front cover. CAUTION To easily remove the cover, raise from the right first, then from the left.

  • Page 111: Removing The Front Mudguard

    CYCLE PARTS SR 50 5.1.6. REMOVING THE FRONT MUDGUARD • Working on the right side, loosen and remove the odometer cord cable guide screw. • Loosen and remove the mudguard front right screw. • Working on the left side, loosen and remove the brake line cable guide screw.

  • Page 112: Removing The Rear Mudguard

    CYCLE PARTS SR 50 5.1.7. REMOVING THE REAR MUDGUARD • Remove the air box, see (REMOVING THE AIR BOX). • Working on the left side, loosen and remove the screw. • Working on the right side, loosen and remove the screw, collect the washer and the spacer.

  • Page 113: Removing The Tool Kit Compartment

    CYCLE PARTS SR 50 5.1.8. REMOVING THE TOOL KIT COMPARTMENT • Lift and remove the tool kit compartment cover. • Unscrew and remove the screw. • Remove the tool kit compartment. 5 - 11 WWW.PlanDeGraissage.ORG...

  • Page 114: Removing The Inner Shield

    CYCLE PARTS SR 50 5.1.9. REMOVING THE INNER SHIELD • Remove the front cover, see (REMOVING THE FRONT COVER). • Release and remove the two screws. • Release and remove the ten screws. • Loosen and remove the two screws of the bag hook.
  • Page 115 CYCLE PARTS SR 50 • Remove rubber element from ignition switch/steering lock. • Slightly raise the inner shield and slide it out of its tabs. • Loosen and remove the two screws securing the seat lock. • Remove the inner shield.

  • Page 116: Removing The Headlight

    CYCLE PARTS SR 50 5.1.10. REMOVING THE HEADLIGHT • Remove the front cover, see (REMOVING THE FRONT COVER). • Release and remove the two screws. • Release and remove the eight screws. • Working on either side, loosen and remove the three inner screws.
  • Page 117 CYCLE PARTS SR 50 • Move the headlight with the two side fairings forward. • Disconnect the two headlight connectors. • Remove the headlight with the two side fairings. 5 - 15 WWW.PlanDeGraissage.ORG...

  • Page 118: Removing The Front Wheelhouse

    CYCLE PARTS SR 50 5.1.11. REMOVING THE FRONT WHEELHOUSE • Remove headlight, (REMOVING HEADLIGHT). • Remove the front wheel, see (REMOVING THE FRONT WHEEL). • Remove the front mudguard, see (REMOVING THE FRONT MUDGUARD). • Release and remove the two front screws.

  • Page 119: Removing The Instrument Panel

    CYCLE PARTS SR 50 5.1.12. REMOVING THE INSTRUMENT PANEL • Release and remove the four front screws. • Remove the headlight fairing. • Release and remove the three top screws. • Release and remove the two lower screws. • Release the handlebar fairing, move it down and keep it connected to the turn indicator wirings.
  • Page 120 CYCLE PARTS SR 50 • Loosen and remove the three screws of the instrument panel subframe. • Remove the instrument panel. 5 - 18 WWW.PlanDeGraissage.ORG...

  • Page 121: Exhaust System

    CYCLE PARTS SR 50 5.2. EXHAUST SYSTEM 5.2.1. REMOVING THE EXHAUST SYSTEM IE361 – C364 • Remove the lower shield, see (REMOVING THE LOWER SHIELD). • Loosen and remove the two studs on the stud bolts. • Working on the right side, loosen and remove the two screws, collect the washers and the spacers.

  • Page 122: Removing The Exhaust System Ie50

    CYCLE PARTS SR 50 5.2.2. REMOVING THE EXHAUST SYSTEM IE50 • Unscrew and remove the screw (1). • Loosen and remove the screw (2). • Loosen and remove the screw (3) securing the silencer to the engine. • Loosen and remove the screw (4) securing the mudguard to the engine.

  • Page 123: Front Wheel

    CYCLE PARTS SR 50 5.3. FRONT WHEEL 5.3.1. FRONT WHEEL DIAGRAM Key: Front wheel rim; Bearing; Inner spacer; Left spacer; Wheel shaft; Tubeless valve; Brake disc; Brake disc screws; Tyre; Drive; Drive seal; Odometer drive fitment; Washer; Nut. 5 - 21...

  • Page 124: Removing The Front Wheel

    CYCLE PARTS SR 50 5.3.2. REMOVING THE FRONT WHEEL WARNING When removing/refitting, pay utmost attention not to damage the brake line, disc and pads. • Position the vehicle on the centre stand. • Set a support under the frame. •...

  • Page 125: Rear Wheel

    CYCLE PARTS SR 50 5.4. REAR WHEEL 5.4.1. REAR WHEEL DIAGRAM Key: Tyre Bare rear wheel Brake disc Tubeless valve Pads Rear brake calliper Air bleed Rear brake line Rear wheel nut Rear wheel plate Ring Pin + calliper spring Bare rear hub ( –...

  • Page 126: Removing The Rear Wheel

    CYCLE PARTS SR 50 5.4.2. REMOVING THE REAR WHEEL • Position the vehicle on the centre stand. • Set a support under the frame. • Remove the exhaust system, see (REMOVING THE EXHAUST SILENCER). • Release and remove the two screws.

  • Page 127: Braking System

    CYCLE PARTS SR 50 5.5. BRAKING SYSTEM 5.5.1. CHANGING THE BRAKE PADS • Position the vehicle on the centre stand. • Remove the brake calliper from the disc, but leave the line connected. For front brake calliper only: • Remove the brake calliper cover.
  • Page 128 CYCLE PARTS SR 50 • Remove the snap ring (1). • Remove the pin (2). • Remove the spring (3). • Remove the pads (4) sliding them out one at a time. WARNING Do not operate the brake lever when the pads...

  • Page 129: Steering

    CYCLE PARTS SR 50 5.6. STEERING 5.6.1. STEERING DIAGRAM Key: Dust seal Lock nut Adjuster nut Upper bearing Lower bearing Steering 5 - 27 WWW.PlanDeGraissage.ORG...

  • Page 130: Front Fork

    CYCLE PARTS SR 50 5.7. FRONT FORK 5.7.1. FRONT FORK DIAGRAM Key: Rubber cap Snap ring Fork clamp bolts Snap ring Sealing cap O-ring Rubber seal Spring Damping cylinder Counter spring Buffer Left slider Right slider Dust seal Snap ring...

  • Page 131: Removing The Fork Leg

    CYCLE PARTS SR 50 5.7.2. REMOVING THE FORK LEG • Remove headlight, (REMOVING HEADLIGHT). • Remove the front wheel, see (REMOVING THE FRONT WHEEL). • Remove the front mudguard, see (REMOVING THE FRONT MUDGUARD). • Release and remove the two inner screws.

  • Page 132: Disassembling The Stanchion

    CYCLE PARTS SR 50 5.7.3. DISASSEMBLING THE STANCHION • Remove the stanchion assembly, see (REMOVING THE FORK LEG). CAUTION Prepare a graduated container with a capacity of at least 300 cu.cm (18.31 cu.in.). • Let the fork leg enter completely in the stanchion, turn the stanchion assembly and let the fluid drain in the container.

  • Page 133: Rear Suspension

    CYCLE PARTS SR 50 5.8. REAR SUSPENSION 5.8.1. REMOVING THE SHOCK ABSORBER • Position the vehicle on the centre stand. 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.
  • Page 134 COOLING SYSTEM SR 50 COOLING SYSTEM 6 - 1 WWW.PlanDeGraissage.ORG...
  • Page 135 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 WWW.PlanDeGraissage.ORG...
  • Page 136 COOLING SYSTEM SR 50 6.1. COOLING SYSTEM 6.1.1. DIAGRAM Key: Expansion tank with plug; Radiator; Expansion tank-radiator hose; Breather hose; Radiator-pump hose; Head-radiator hose; To water pump; From head. 6 - 3 WWW.PlanDeGraissage.ORG...
  • Page 137 COOLING SYSTEM SR 50 6.2. EMPTYING THE COOLING SYSTEM 6.2.1. EMPTYING THE COOLING SYSTEM CAUTION Before proceeding with cooling system emptying, it is necessary to take a container having a suitable capacity. • Remove the front cover, see (REMOVING THE FRONT COVER).
  • Page 138 ELECTRICAL SYSTEM SR 50 ELECTRICAL SYSTEM 7 - 1 WWW.PlanDeGraissage.ORG...
  • Page 139 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.

  • Page 140: Checking The Electrical Components

    ELECTRICAL SYSTEM SR 50 7.1. CHECKING THE ELECTRICAL COMPONENTS 7.1.1. CHECKING THE COMPONENTS IE361 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) Rpm sensor:...
  • Page 141 ELECTRICAL SYSTEM SR 50 Starter motor current absorbed in operation 20 A Fuel pump: absorption 0.35 A Tail light: parking/stop light 12 V – 5 / 21 W Ignition coil: primary resistance: 0.7 ohm 7 - 4 WWW.PlanDeGraissage.ORG...
  • Page 142 ELECTRICAL SYSTEM SR 50 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 Fuses: 10A fuse (1) - From ignition switch to: •...
  • Page 143 ELECTRICAL SYSTEM SR 50 Throttle body FUEL INJECTOR winding resistance: 1.7 ohm THROTTLE POSITION SENSOR (TPS): resistance across terminals 1 and 4: 1.1 kohm Throttle grip CLOSED resistance across terminals 1 and 2: 1.1 kohm resistance across terminals 1 and 3: 1.9 kohm Throttle grip OPEN resistance across terminals 1 and 2: 1.9 kohm...

  • Page 144: Checking The Components Ie50

    ELECTRICAL SYSTEM SR 50 7.1.2. CHECKING THE COMPONENTS IE50 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) Rpm sensor: inductive sensor winding resistance: 110 ohm 7 - 7 WWW.PlanDeGraissage.ORG...
  • Page 145 ELECTRICAL SYSTEM SR 50 Starter motor current absorbed in operation 20 A Fuel pump: absorption 0.35 A Tail lights: parking/stop light 12 V – 5 / 21 W Ignition coil: primary resistance: 0.7 ohm 7 - 8 WWW.PlanDeGraissage.ORG...
  • Page 146 ELECTRICAL SYSTEM SR 50 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 Fuses: 10A fuse (1 - 2) - From ignition switch to: •...
  • Page 147 ELECTRICAL SYSTEM SR 50 Throttle body FUEL INJECTOR winding resistance: 1.7 ohm THROTTLE POSITION SENSOR (TPS): resistance across terminals 1 and 4: 1.1 kohm Throttle grip CLOSED resistance across terminals 1 and 2: 1.1 kohm resistance across terminals 1 and 3: 1.9 kohm Throttle grip OPEN resistance across terminals 1 and 2: 1.9 kohm...

  • Page 148: Checking The Components C364

    ELECTRICAL SYSTEM SR 50 7.1.3. CHECKING THE COMPONENTS C364 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) Rpm sensor: inductive sensor winding resistance: 110 ohm 7 - 11 WWW.PlanDeGraissage.ORG...
  • Page 149 ELECTRICAL SYSTEM SR 50 Starter motor absorption in operation: 20 A. Tail lights: parking/stop light 12 V – 5 / 21 W Fuel sensor: resistance (measure across pin 1 and 2) ohm with full fuel tank 100 ohm with empty fuel tank...
  • Page 150 ELECTRICAL SYSTEM SR 50 Headlight: low beam 12 V – 35 W high beam 12 V – 35 W Engine temperature sensor: NTC sensor resistance: 560 ohm (at 25°C) resistance: 40 ohm (at 100°C) 7 - 13 WWW.PlanDeGraissage.ORG...

  • Page 151: Wiring System Diagrams

    ELECTRICAL SYSTEM SR 50 7.2. WIRING SYSTEM DIAGRAMS 7.2.1. WIRING DIAGRAM IE 361 7 - 14 WWW.PlanDeGraissage.ORG...
  • Page 152 ELECTRICAL SYSTEM SR 50 Key: Multiple connectors Low-high beam relay Oil level switch Fuel level sensor Instrument panel (matrix) Immobilizer antenna Key-operated switch Warning horn Left dimmer switch Rear stop switch (on left dimmer switch) Right dimmer switch Front stop switch (on right dimmer switch)
  • Page 153 ELECTRICAL SYSTEM SR 50 7.2.2. WIRING DIAGRAM IE 50 7 - 16 WWW.PlanDeGraissage.ORG...
  • Page 154 ELECTRICAL SYSTEM SR 50 Key: Multiple connectors Oil level switch Fuel level sensor Instrument panel (matrix) Immobilizer antenna Key-operated switch Warning horn Left dimmer switch Rear stop switch (on left dimmer switch) Right dimmer switch Front stop switch (on right dimmer switch)
  • Page 155 ELECTRICAL SYSTEM SR 50 7.2.3. WIRING DIAGRAM C 364 7 - 18 WWW.PlanDeGraissage.ORG...
  • Page 156 ELECTRICAL SYSTEM SR 50 Key: Multiple connectors Speed sensor Fuel level sensor Instrument panel (easy) Head temperature sensor Oil level switch Key ignition switch Warning horn Left dimmer switch Rear stop switch (on left dimmer switch) Right dimmer switch Front stop switch (on right dimmer switch)
  • Page 157 G.Galilei, 1 30033 Noale (VE) Italy tel. +39 041.5829111 fax +39 041.5829190 www.aprilia.com www.serviceaprilia.com WWW.PlanDeGraissage.ORG...

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