APRILIA SX 50 Workshop Manual
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APRILIA SX 50 Workshop Manual

APRILIA SX 50 Workshop Manual

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WORKSHOP MANUAL
8140927
SX-RX 50

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Summary of Contents for APRILIA SX 50

  • Page 1 WORKSHOP MANUAL 8140927 SX-RX 50...

  • Page 2: Workshop Manual

    The descriptions and illustrations given in this publication are not binding; While the basic characteristics as described and illustrated in this manual remain unchanged, aprilia reserves the right, at any time and without being required to update this publication beforehand, to make any changes to components, parts or accessories, which it considers necessary to improve the product or which are required for manufacturing or construction reasons.
  • Page 3 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.

  • Page 5: Index Of Topics

    INDEX OF TOPICS CHAR HARACTERISTICS TOOL OOLING MAIN AINTENANCE TROUBL ROUBLESHOOTING ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE NGINE SUSP USPENSIONS BRAK SYS RAKING SYSTEM COOL SYS OOLING SYSTEM CHAS HASSIS PRE DE DELIVERY...
  • Page 6 INDEX OF TOPICS CHAR HARACTERISTICS...
  • Page 7 SX-RX 50 Characteristics Vehicle identification Chassis prefix The chassis number is stamped on the right side of the headstock. RX: ZD4PVA00XXXXX SX: ZD4PV000XXXXX Dimensions and mass RX SIZE Specification Desc./Quantity Width 825 mm (32.48 in) Max. length 2100 mm (82.68 in) Max.
  • Page 8 SX-RX 50 Characteristics Specification Desc./Quantity Cooling With coolant Lubrication Thermal group: With oil for 2T engines through variable pump capacity Transmission: gear reduction units in oil bath for transmis- sions CARBURETTOR Dell'Orto PHVA-17.5 with manual starter Admission Reed valve direct to crankcase Gear 6-speed transmission with selector fork and drum distributor operated by external control...

  • Page 9: Wheels And Tyres

    SX-RX 50 Characteristics Brakes BRAKES Specification Desc./Quantity Front wheel brakes: Hydraulic disc brakes Ø 260 mm (RX) Ø 300 mm (SX) Rear wheel brakes: Ø 180 mm hydraulic disc brake Wheels and tyres WHEELS AND TYRES Specification Desc./Quantity Rear tyre: 110/80 x 18'' (RX) 130/70 x 17'' (SX) Front tyre:...
  • Page 10 SX-RX 50 Characteristics Name Torque in Nm Fork leg cover 17-19 Muffler to cylinder 9-12 muffler to chassis clamp 17-19 Muffler silencer to chassis 17-19 Steering arm - fork bar clamp 20-24 Handlebar to steering arm 20-24 Front wheel axle 70-80 Front brake calliper 17-19...
  • Page 11 INDEX OF TOPICS TOOL OOLING...
  • Page 12 SX-RX 50 Tooling OOLS Stores code Description 020376Y Adapter handle 020357Y 32 x 35 mm adaptor 020441Y Oil seal punch 020456Y Ø 24 mm punch 020358Y 37 x 40-mm adaptor 020426Y Piston fitting fork TOOL - 12...
  • Page 13 SX-RX 50 Tooling Stores code Description 020455Y 10-mm guide for oil seal on water pump shaft 020362Y 12-mm Oil seal guide 020412Y 15-mm Oil seal guide 020439Y 17-mm guide for oil seal 020363Y 20-mm Oil seal guide 0.0H.053.0.004.1 Clutch locking tool 0.0H.056.0.032.1 Main transmission pinion extractor TOOL - 13...
  • Page 14 SX-RX 50 Tooling Stores code Description 020565Y Flywheel lock calliper spanner AP8106698 Crankcase separator AP8501501 Flywheel extractor 020330Y Stroboscopic light for timing checking 020331Y Digital multimeter 020333Y Single battery charger TOOL - 14...
  • Page 15 SX-RX 50 Tooling Stores code Description 020334Y Multiple battery charger TOOL - 15...

  • Page 16: Maintenance

    INDEX OF TOPICS MAIN AINTENANCE...

  • Page 17: Maintenance Chart

    SX-RX 50 Maintenance Maintenance chart AFTER 1000 KM Action Coolant - Check Air filter - cleaning Odometer gear - grease Steering - check up Brake control levers - Grease Brake pads - check Gearing chain - Grease Gearing chain tension - check Safety locks - check Front fork - Check Electrical system and battery - Check...

  • Page 18: Every 2 Years

    SX-RX 50 Maintenance Action Tyre condition and wear - Check Wheel - Check Tyres pressure - Check Oil filter - Replacement Fuel and oil hoses - Replacement Vehicle and brake test - test drive Engine oil - Change Spark plug - replacement Carburettor - Adjustment Clutch control lever - Adjustment 15,000;...
  • Page 19 SX-RX 50 Maintenance KEY: 1. Starter 2. Idle air set screw 3. Idle set screw 4. Throttle valve spring 5. Throttle valve tapered pin 6. Throttle valve 7. Carburettor body 8. Pin 9. Minimum jet 10. Float 11. Starter jet 12.

  • Page 20: Spark Plug

    SX-RX 50 Maintenance - If there are wear marks in the mix chamber causing inadequate tightness or valve slide (even if it is new), replace the carburettor. - It is advisable to replace the gasket at each refit WARNING PETROL IS HIGHLY EXPLOSIVE ALWAYS REPLACE THE GASKETS TO AVOID PETROL LEAKS Checking the spark advance Engine timing control - Remove the crankcase left cover.

  • Page 21: Air Filter

    SX-RX 50 Maintenance Characteristic Spark plug NGK BR8 ES - Insert the spark plug manually to avoid damaging the thread, and press it slightly with the adequate spanner. Locking torques (N*m) Spark plug 20÷24 Air filter Check filter for cleaning and condition every 5000 km and every time the vehicle is used off-road.
  • Page 22 SX-RX 50 Maintenance IF THE FILTER IS OBSTRUCTED, THE ADMISSION RE- SISTANCE WILL INCREASE, LEADING TO POWER LOSS AND HIGHER FUEL CONSUMPTION. Recommended products AGIP FILTER OIL Oil for air filter sponge Cleaning - Wash the sponge with water and mild soap. - Dry it with a clean cloth and short blasts of com- pressed air.

  • Page 23: Braking System

    SX-RX 50 Maintenance Rear wheel axle Set screw 70-80 17÷19 Transmission adjustment - Adjust the control cables: - Mixer cable: see "Mixer timing" section. - Throttle cable: adjust it so that the sheath has no backlash. - Splitter control cable: Adjust it so that there is no backlash on the throttle. - All transmissions should be adjusted so that their relative sheaths have no backlash.
  • Page 24 SX-RX 50 Maintenance Front brake oil level check Proceed as follows: - Rest the scooter on its centre stand with the han- dlebars perfectly horizontal; - Check the fluid level through the corresponding sight glass (A). Topping up brake fluid Proceed as follows: - Remove the tank cap by loosening the two screws, remove the gasket and top up using only...
  • Page 25 SX-RX 50 Maintenance Front brake oil level check Proceed as follows: - Position the scooter upright. - Check fluid level through the references on the brake fluid reservoir body. Topping up brake fluid Proceed as follows: - Remove the screw of the reservoir cap, remove the gasket and fill up using only the specified fluid, without exceeding the maximum level.

  • Page 26: Headlight Adjustment

    SX-RX 50 Maintenance Headlight adjustment - Position the scooter with rider on flat ground, 10 m away from a half-lit white screen. - Make sure that the scooter's axle is perpendicular to the screen. - Measure the distance from the centre of the headlight to the ground and then mark a cross on the wall at the same height measured.
  • Page 27 SX-RX 50 Maintenance - Pour out the oil in the main transmission gear- case through the filler cap (1) Characteristic Capacity: 0.65 l MAIN - 27...

  • Page 28: Troubleshooting

    INDEX OF TOPICS TROUBL ROUBLESHOOTING...

  • Page 29: Poor Performance

    SX-RX 50 Troubleshooting Engine Poor performance POOR PERFORMANCE Possible Cause Operation Fuel nozzles or valve clogged or dirty. Dismantle, wash with solvent and dry with compressed air Excess of encrustations on the cylinder ports and in the com- Descale the thermal unit. bustion chamber.
  • Page 30 SX-RX 50 Troubleshooting Possible Cause Operation Bear in mind that many engine problems derive from the use of an inadequate spark plug. Engine tends to cut-off at idle NGINE TENDS TO STOP AT IDLE SPEED Possible Cause Operation Minimum nozzle dirty Wash the nozzle with solvent and dry with compressed air Starter that stays open Check the mechanical movement.
  • Page 31 SX-RX 50 Troubleshooting Battery ATTERY Possible Cause Operation Battery This is the device in the system that requires the most frequent monitoring and most careful maintenance. Frequently check that the fluid level completely covers the plates, otherwise top it up with distilled water (never use natural water, even if pota- ble) and also check the fluid for correct density.

  • Page 32: Electrical System

    INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
  • Page 33 SX-RX 50 Electrical system KEY: 1. Electronic ignition device 2. Spark plug 3. Voltage regulator 4. Magneto flywheel 5. Key switch 6. Main fuse 7. Battery 8. Horn 9. Horn button 10. Electric fan pre-installation 11. STOP button on rear brake 12.

  • Page 34: Electrical System Installation

    SX-RX 50 Electrical system 20. Light switch 21. Instrument panel 22. Timer 23. Engine temperature warning light control 24. Low oil warning light control 25. Fuel level warning light control 26. Automatic starter pre-installation O = Orange, SB = Sky Blue, W = White, B = Blue, Y = Yellow, Gr = Grey, Br = Brown, Bl = Black, P = Pink, R = Red, G = Green, Pr = Purple Dashboard SERVICE WARNING LIGHT RESET...
  • Page 35 SX-RX 50 Electrical system - Detach the electric connections and remove the switch/lock unit. Conceptual diagrams Ignition KEY: 1. Electronic ignition device 2. Spark plug 4. Magneto flywheel 5. Key switch ELE SYS - 35...
  • Page 36 SX-RX 50 Electrical system Headlights and automatic starter section KEY: 3. Voltage regulator 4. Magneto flywheel 5. Key switch 15. Tail light/stop light bulb 18. High-beam/low-beam light bulb 20. Light switch 21. Instrument panel 26. Automatic starter pre-installation ELE SYS - 36...
  • Page 37 SX-RX 50 Electrical system Battery recharge and starting KEY: 3. Voltage regulator 4. Magneto flywheel 6. Main fuse 7. Battery ELE SYS - 37...
  • Page 38 SX-RX 50 Electrical system Level indicators and enable signals section KEY: 3. Voltage regulator 5. Key switch 6. Main fuse 7. Battery 21. Instrument panel 22. Timer 23. Engine temperature warning light control 24. Low oil warning light control 25. Fuel level warning light control ELE SYS - 38...
  • Page 39 SX-RX 50 Electrical system Turn indicators and horn 3. Voltage regulator 4. Magneto flywheel 5. Key switch 6. Main fuse 7. Battery 8. Horn 9. Horn button 13. Turn indicator switch 14. Left turn rear indicator lamp 16. Right turn rear indicator lamp 17.

  • Page 40: Devices And Accessories

    SX-RX 50 Electrical system E. Low fuel warning light F. Instrument panel bulb Devices and accessories KEY: 3. Voltage regulator 4. Magneto flywheel 5. Key switch 6. Main fuse 7. Battery 8. Horn 9. Horn button 13. Turn indicator switch 14.

  • Page 41: Checks And Inspections

    SX-RX 50 Electrical system Checks and inspections In case the cause of ignition failure or malfunction cannot be easily identified at sight, first of all re- place the control unit by another one in operating conditions. Remember that disconnections due to replace- ment of the central unit must be done with the engine off.

  • Page 42: Stator Check

    SX-RX 50 Electrical system - Check the resistance of the secondary winding of the high voltage coil (resistance between points A and B) WARNING IF THE READINGS OF THE SECONDARY WINDING AND THE MAGNETO FLYWHEEL ARE RIGHT, REPLACE THE COIL. Electric characteristic Resistance 5 - 6 kOhm...
  • Page 43 SX-RX 50 Electrical system - Check that the resistance between terminals and the ground complies with the values indicated in the table. Lights list BULBS Specification Desc./Quantity Front headlamp bulbs 12V. 35/35 W. Type: Double filament Tail light/stop bulb 12 V, 21/5 W Type: Double filament Turn indicator bulb 12 V, 10 W...
  • Page 44 SX-RX 50 Electrical system 2) Constant voltage battery charge mode -Constant voltage equal to 14.40 ÷ 14.70V -Initial charge voltage equal to 0.3 ÷ 0.5 x nominal capacity -Duration of the charge: 10 to 12 h recommended Minimum 6 h Maximum 24 h 3) Constant current battery charge mode -Charge current equal to 1/10 of the nominal ca-...
  • Page 45 SX-RX 50 Electrical system 5. Once the above operations have been performed, install the battery on the vehicle ensuring that it is wired up properly. WARNING - ONCE THE BATTERY HAS BEEN INSTALLED ON THE VEHICLE IT IS NECESSARY TO RE- PLACE THE SHORT TUBE (WITH CLOSED END) NEAR THE + POSITIVE TERMINAL WITH THE CORRESPONDING LONG TUBE (WITH OPEN END), THAT YOU FIND FITTED TO THE VEHICLE, TO ENSURE THAT THE GASES THAT FORM CAN ESCAPE PROPERLY.

  • Page 46: Battery Installation

    SX-RX 50 Electrical system Regular charging must be carried out with the specific battery charger (single or multiple), setting the battery charger selector to the type of battery to be recharged. Connections to the power supply source must be implemented by connecting corresponding poles (+ to + and - to -). 4) Cleaning the battery The battery should always be kept clean, especially its top side, and the terminals should be coated with petroleum jelly.
  • Page 47 SX-RX 50 Electrical system Check the electrolyte level. This level must be checked frequently and must reach the max. level. Use only distilled water to restore this level. If it is necessary to add water too frequently, check the vehicle electrical system: the battery works over- charged and is subject to quick wear.

  • Page 48: Index Of Topics

    INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
  • Page 49 SX-RX 50 Engine from vehicle Exhaust assy. Removal - Remove the left side fairing - Remove the screws that fix the muffler to the cyl- inder - Remove the screws that fix the silencer to the muffler - Remove the clamp that fixes the muffler to the chassis - Remove the clamp that fixes the silencer to the chassis...
  • Page 50 SX-RX 50 Engine from vehicle Removal of the engine from the vehicle - Remove all plastic components around the fuel tank. - Pay attention to the couplings between the plastic components, the fuel tank and the radiator pro- tecting grille. - Remove the exhaust tube with the silencer.
  • Page 51 SX-RX 50 Engine from vehicle - Remove the carburettor: • Remove the fuel pump control low- pressure pipe • Remove the fuel hoses • Remove the mixer oil hoses - Remove the cable from the clutch lever. - Before removing the cable, loosen the lever - hand grip unit set screw.
  • Page 52 SX-RX 50 Engine from vehicle - Remove the oil from the gearbox. The oil drain- age cap is in the lower part of the crankcase. - Remove the drive using the fake link shown in the picture. - Take note of the correct positioning during the refit phase.
  • Page 53 SX-RX 50 Engine from vehicle - Remove the engine from the chassis by pulling forward and turning it slightly. ENG VE - 53...
  • Page 54 INDEX OF TOPICS NGINE...

  • Page 55: Removing The Starter Motor

    SX-RX 50 Engine Flywheel and starting Removing the starter motor - Remove the transmission gear collecting the shimming - Unload the spring and remove the start-up mech- anism Removing the flywheel magneto - Remove the gear pedal - Undo the three fixings screws and remove the left crankcase cover - Lock the magneto flywheel with the aid of a spe- cific calliper spanner.
  • Page 56 SX-RX 50 Engine - Remove the flywheel with the specific extractor Specific tooling AP8501501 Flywheel extractor - Detach the connector between stator and the clamps fixing the wire to the chassis - Undo the three fixings screws and remove the stator from stator plate - Undo the three fixing screws of the plate in order to detach the stator electrical cable...
  • Page 57 SX-RX 50 Engine - Connect the stator connector and fix the wire to the chassis by means of the clamps - Make sure the cable support inside the crankcase is correctly positioned so that the cables do not get into contact with the flywheel rotor - Mount the flywheel checking the proper insertion of the key in the slot on the crankshaft - Lock the flywheel with the aid of a specific calliper...

  • Page 58: Removing The Cylinder Head

    SX-RX 50 Engine Removing the cylinder head - Remove the coolant rubber pipes connecting the pump and the radiator and collect the coolant - Remove the rubber pipes connecting the head and the radiator - Disconnect the electrical connector of the tem- perature sensor - Remove the spark plug - Undo the five fixing screws to remove the head...
  • Page 59 SX-RX 50 Engine - Bleed the system Locking torques (N*m) Stud bolts: 19 Nm Screws 6 Nm Thermal switch 10 Nm Removing the cylinder - piston assy. - Empty the coolant out the system - Remove the cylinder head - Remove the cylinder by slowly sliding it upwards - Remove the base gasket - Put a piece of old cloth in the cylinder housing hole on the crankcase so that no object can fall in...
  • Page 60 SX-RX 50 Engine Inspecting the piston - Check the piston outside diameter following the perpendicular axis to the pin seat. Measure at 15 mm from the lowest seat of a circlip Characteristic Serviceability limit: 0.01 mm Inspecting the cylinder - Measure the openings of the piston elastic seal- ing rings by placing a thickness gauge in the cyl- inder Characteristic...

  • Page 61: Removing The Piston

    SX-RX 50 Engine TYPE C Specification Desc./Quantity Piston 39,860 +/- 0,0025 mm Cylinder 39,900 +/- 0,0025 mm TYPE D Specification Desc./Quantity Piston 39,865 +/- 0,0025 mm Cylinder 39,905 +/- 0,0025 mm Removing the piston - Refit the piston sealing circlips - Fit a new cylinder base gasket - Refit the ball retainer at the rod small end and make sure to lubricate the components with rec-...
  • Page 62 SX-RX 50 Engine - Remove the start-up pedal - Dismantle the rear brake pedal - Detach the hose connecting the radiator to the hydraulic pump and flow out the coolant of the cooling system - Disconnect the clutch lever wire and remove the clutch wire clamp - Flow out the oil in the gearbox and in the clutch - Remove the oil pump cover...
  • Page 63 SX-RX 50 Engine - The longer screws are highlighted in the figure - Remove the crankcase cover gasket and clean off any rests of old gaskets that may remain on the crankcase or the cover - Slide off and remove the clutch lever from the clutch cover - Undo the two fixing screws of the hydraulic pump and remove the pump...
  • Page 64 SX-RX 50 Engine - First unscrew the fixing nut and then the rotor. Remove the driving gear - Slide out the hydraulic pump shaft and its oil seals ENG - 64...
  • Page 65 SX-RX 50 Engine - Remove the transmission gear - Remove the driving gear and the oil pump shaft Installing the crankcase - On the cover, install the hydraulic pump shaft together with the outer seeger ring, fitting it from the rotor side - Mount the driving gear - Fit new oil seals on the hydraulic pump shaft with...
  • Page 66 SX-RX 50 Engine - Mount the oil pump shaft following the same pro- cedure as for removal but in reverse order - It is crucial to check that the shim washers are correctly mounted - Mount the transmission and the driving gear - Fit a new oil seal in the clutch lever seat on the cover - Fit the clutch lever...
  • Page 67 SX-RX 50 Engine - Fit the clutch wire, the clamp and the lever - Turn the clutch control clockwise with a screw- driver and then fit the clutch lever and its screws - Adjust the clutch lever backlash at a value rang- ing from 2 to 4 mm (handlebar left-hand side) - Mount the hose connecting the hydraulic pump to the radiator and that connecting the hydraulic pump to the cylinder...
  • Page 68 SX-RX 50 Engine - Fill up the cooling system with the recommended coolant Removing the clutch - Remove the crankcase right cover - Undo the 5 screws fixing the clutch spring and lift the internal clutch cover - Remove the 4 clutch plates and the three steel discs - Straighten the bevelled washer - Lock the disc thrust plate with the specific tool...
  • Page 69 SX-RX 50 Engine - Check the clutch spring - Measure the length of each spring when exten- Characteristic Spring serviceability limit : 31 mm - Check the clutch plate - Measure each plate thickness Characteristic Serviceability limit : 3.8 mm ENG - 69...
  • Page 70 SX-RX 50 Engine - Check the steel discs - Use thickness gauges to check that the plates are not deformed Characteristic Serviceability limit : 0.15 mm Carry out a visual inspection of the clutch jaws. Replace the component if there are signs of ther- mal fatigue, reduced surface hardness or irregular jaw wear.
  • Page 71 SX-RX 50 Engine - Fit the shim washer and the clutch bushing - Fit the clutch bell. Initially, it should be aligned with the gear of the main transmission (2), and then, after manually turning the intermediate gear of the kick starter (4), should be aligned with the lower gear of the clutch bell - Fit the star washer - Fit the disc thrust plate, the bevelled washer and...
  • Page 72 SX-RX 50 Engine - Lubricate the clutch plates with new oil - Fit the plates with the visible mark on one of the friction surfaces facing out - Fit the clutch springs and their fixing screws - Tighten to the specified torque Locking torques (N*m) Clutch cover screws 8 -10 Nm...
  • Page 73 SX-RX 50 Engine - Remove the crankcase left cover - Lock the magneto flywheel with the specific tool. If the flywheel has been already removed, reposi- tion it on the shaft only for this operation Specific tooling 020565Y Flywheel lock calliper spanner - Unscrew and remove the nut fixing the crankshaft pinion - Smontare l'ingranaggio della trasmissione pri-...
  • Page 74 SX-RX 50 Engine Selector unit removal - Take out the clutch assembly - Remove the gear pedal - Pull and extract the shaft/selector unit together with its shimming - Undo the screw of the gear selector lever - Undo the screw of the drum control head ENG - 74...
  • Page 75 SX-RX 50 Engine - Check that the selector shaft is not worn or dam- aged - Mount the components following the removal procedure but in reverse order - Apply one drop of Loctite 270 on the thread of the screw of the drum control head - Make sure that the selector shaft springs and the gear selector lever spring have been correctly fit- Crankshaft removal...
  • Page 76 SX-RX 50 Engine - Take out the selector guiding fork and the selec- tor after removing the relative bolts - Remove the selector - Take out the two gear shafts simultaneously - Warm the crankshaft seat on the clutch side at about 60°...
  • Page 77 SX-RX 50 Engine - Thoroughly clean and degrease the crankshaft and then check it - Use a thickness gauge to check the clearance between the rod head and the half shaft Characteristic Serviceability limit: 0.8 mm - Use a comparator to check the clearance be- tween the connecting rod and the crankpin on X and Y axis as indicated in the photograph Characteristic...
  • Page 78 SX-RX 50 Engine - Take out the gears and the shim washers of the secondary shaft once the locks have been re- moved - Check there gear studs and clefts are not roun- ded or show signs of abnormal wear - Check the secondary shaft rings for wear - Replace them if 25% of their surface is worn - Make sure that the secondary shaft roller bear-...
  • Page 79 SX-RX 50 Engine - Clean and lubricate the main bearings - Replace them if there are signs of abnormal wear, deformations or jams. - Thoroughly clean and degrease all the compo- nents of the gear housing, the selector and the shaft - Reassemble the secondary shaft making sure all components are fitted correctly...
  • Page 80 SX-RX 50 Engine - Fit the selector. Lubricate the surfaces with spe- cific oil - Make sure that the gear housing works properly by selecting different speeds and turning the drum to both sides - Select neutral gear and check that the system rotates freely - Reassemble the crankcase by warming up the shaft seats at about 60°...
  • Page 81 SX-RX 50 Engine - Remove the oil pump cover located on the engine crankcase - Remove the oil inlet and delivery hoses to the pump by operating the flexible clamps - Be careful to close the oil pipe going to the pump so that the reservoir does not get empty - Remove the pump opening control cable by op- erating the set screw first and then the pump cam...

  • Page 82: Fuel Supply

    SX-RX 50 Engine Oil pump purging - Check oil in the reservoir for correct level; top up with recommended oil if necessary - Place a suitable container under the pump to col- lect the oil purged from the pump - Loosen the oil pump bleed screw (1), located at the front of the pump between the inlet and the delivery pipes, to facilitate drainage until the oil flow is constant and no air bubbles are formed.
  • Page 83 SX-RX 50 Engine - Remove the carburettor from the engine - Remove the reed valve and its gaskets from the crankcase - Check that the valve petals are not damaged or deformed. Otherwise, replace it. - Remove the plate limiting the reed valve opening by undoing the three screws fixing the reeds ENG - 83...
  • Page 84 SX-RX 50 Engine - Mount the valve following the removal procedure but in reverse order, make sure the plate limiting the reed valve opening has been correctly posi- tioned - Absence of the plate limiting the reed valve open- ing compromises the engine performance and re- liability - Check the O-ring of the reed support.
  • Page 85 SX-RX 50 Engine - Undo the two screws to remove the throttle valve and the tapered pin as well - Compress the throttle valve return spring - Remove the safety cap of the throttle valve and remove the throttle control cable from the throttle - Remove the fixing plate of the starter control by undoing the screws indicated in the photograph - Remove the starter control...
  • Page 86 SX-RX 50 Engine - Remove the air flow set screw as indicated in the photograph - Remove the carburettor float chamber - Remove the float by operating the stem that fixes it to the carburettor with a very thin pin - Remove the maximum nozzle, the idle nozzle and the starter nozzle Refitting the carburettor...
  • Page 87 SX-RX 50 Engine - Blow short blasts of compressed air through all the nozzles of the carburettor, including the oil and petrol intake ones - Use scales to check the float weight. Weight: 3.5 - Replace the float if higher weight values are found - Check that the tapered pin is in good conditions.
  • Page 88 SX-RX 50 Engine - Check the starter control pistons are in good con- ditions - Replace them if they show signs of abnormal wear - Check that the calibration of the nozzles is ade- quate (see the carburettor calibration table) - Failure to respect these values compromises en- gine performance - Check that the stop is correctly positioned on the...

  • Page 89: Adjusting The Idle

    SX-RX 50 Engine - Check that idle set screw shows no signs of ab- normal wear. This is detrimental to a correct idle speed adjustment - Check that the throttle valve shows scratches comprising 25% of its overall surface. Otherwise, replace it.

  • Page 90: Index Of Topics

    INDEX OF TOPICS SUSP USPENSIONS...
  • Page 91 SX-RX 50 Suspensions Front Front suspension removal - Remove the stem and the fork leg from the fork plate. - Secure the stem in the vice appropriately with aluminium clamps to avoid scratching the stem. - Loosen the upper screw. - Remove the stem upper clamp together with the preload bushing.
  • Page 92 SX-RX 50 Suspensions - Remove the dust guard with the aid of a screw- driver. - Remove the lower screw on the fork leg in order to free the stem from the fork leg. - Remove the stem from the fork leg. - Remove the aluminium bushing that guides the stem in the fork leg.
  • Page 93 SX-RX 50 Suspensions - Extract the hydraulic cartridge from the upper part of the stem. - Lock the fork leg in the vice making sure to use two aluminium clamps to avoid scratching the fork leg. - Place a protection cloth on the fork leg rim and remove the oil guard as indicated in the picture.
  • Page 94 SX-RX 50 Suspensions - Prepare a support with two gauging blocks in X. - Position the stem as shown in the photograph and use a comparator to check alignment. Serviceability limit: 0.2 mm. - Check the length of the fork spring. - Check that the spring does not show sings of wear or deformation.
  • Page 95 SX-RX 50 Suspensions Name Torque in Nm Fork plate lower clamp 8 ÷ 10 Nm Front wheel axle 70-80 Front brake calliper clamps 17 ÷ 19 Nm * Rear - The rear shock absorber assembly does not re- quire maintenance. Replace it if there are any signs of malfunctioning - For the RCR version, the rear suspension main- tenance must be carried out frequently, and espe-...
  • Page 96 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...

  • Page 97: Rear Brake Calliper

    SX-RX 50 Braking system Rear brake calliper Rear brake calliper replacement - Support the scooter rearcarriage adequately so that the rear wheel does not touch the ground. - Detach the oil brake hose from calliper, pouring the fluid inside a container. - Remove the wheel axle operating the nut indica- ted in the photograph.

  • Page 98: Front Brake Disc

    SX-RX 50 Braking system Front brake disc Brake disc replacement - Dismantle the front wheel undoing the axle lock- ing screw and the wheel axle nut as indicated in the photograph. - Undo the six disc clamps. - Upon refitting, place the disc correctly, that is, following the rotation direction.

  • Page 99: Front Brake Pads

    SX-RX 50 Braking system Front brake pads - To facilitate this operation, remove the two cal- liper retainers shown in the figure. - Remove the two pad locks once the calliper has been removed from the support though still con- nected to the oil pipe.

  • Page 100: Rear Brake Pads

    SX-RX 50 Braking system Rear brake pads Brake pad replacement - Support the scooter rearcarriage adequately so that the rear wheel does not touch the ground. - Remove the rear wheel axle undoing the nut in- dicated in the photograph. - Remove the two pad locks once the calliper has been removed though still connected to the oil pipe.
  • Page 101 SX-RX 50 Braking system Rear - combined Oil refill and purging - Once the bleed valve is closed, fill the system with TUTELA TOP 4 brake fluid to its maximum level. - Loosen the bleed screw. - Connect the pipe of the special tool to the bleed screw.
  • Page 102 SX-RX 50 Braking system THE BRAKING CIRCUIT FLUID IS HYGROSCOPIC, IN OTHER WORDS, IT ABSORBS HUMIDITY FROM THE SURROUNDING AIR. IF THE CONTENT OF MOISTURE IN THE BRAKING FLUID EX- CEEDS A CERTAIN VALUE, BRAKING WILL BE INEFFICIENT. Specific tooling 020329Y Vacuum pump Mity-Vac Front - Loosen the bleed screw.

  • Page 103: Front Brake Pump

    SX-RX 50 Braking system Specific tooling 020329Y Vacuum pump Mity-Vac -Once the bleed valve is closed, fill the system with brake liquid to the maximum level. Front brake pump - Undo the two retainers of the U bolt (see figure). - Disconnect the tube, collecting the brake oil in a container.

  • Page 104: Cooling System

    INDEX OF TOPICS COOL SYS OOLING SYSTEM...

  • Page 105: Coolant Replacement

    SX-RX 50 Cooling system Coolant replacement - Connect the hose to the hydraulic pump and to the radiator - Lift the tank cover, remove the cap and fill the tank with the recommended coolant - Loosen the bleed screw on the pump cover and screw it again - Start the engine and let it reach the regular op- erating temperature.
  • Page 106 SX-RX 50 Cooling system - Detach the gasket (1) - Undo the rotor screw (2) - Undo the hydraulic pump rotor (3) - Drain out all the oil from the engine - Remove the crankcase right cover - Remove the shaft of the hydraulic pump (1) and the transmission pinion (2) - As soon as there is the slightest indication of coolant or oil leaking from the breather, replace the...
  • Page 107 SX-RX 50 Cooling system - Install the hydraulic pump shaft and the trans- mission pinion - Fit the washer (3) - Fit the crankcase cover - Fit the rotor of the pump (1) and its screw Locking torques (N*m) Pump rotor: 2 Nm - Fit the gasket on the pump cover, the cover and the two couplings - Pour recommended oil in the transmission...
  • Page 108 SX-RX 50 Cooling system - Replace the thermostat if the results do not co- incide with the specified values Characteristic Valve opens at 67±3 °C : 0.1 mm Valve opens at 75°C : 3 mm Thermostat check - Immerse the thermal switch in hot water to check its resistance - The thermostat should not get into contact with the container walls or bottom, otherwise the read-...
  • Page 109 INDEX OF TOPICS CHAS HASSIS...
  • Page 110 SX-RX 50 Chassis Seat To remove the saddle, insert the key in the tank cover lock «1» and, while turning it to the right, lift the cover. After that, remove the two fixing knobs from the saddle «2». The oil reservoir, the battery and the toolkit com- partment are under the saddle.
  • Page 111 SX-RX 50 Chassis - Remove the headlight central fixing/set screw - Remove the fixing screws of the turn indicator support bracket from the glass Replacing the front headlight - After removing the headlight glass, undo the con- nectors indicated in the picture and the headlight fixing/set screw in order to remove the headlight CHAS - 111...

  • Page 112: Side Fairings

    SX-RX 50 Chassis Footrest Passenger footrest replacement - Remove the screws indicated in the figure and remove the passenger footrests. Side fairings Side fairings Remove the three fixing screws shown in the fig- ure. Front fairing replacement - To substitute the half-fairings, remove the fixing screws indicated in the figure CHAS - 112...
  • Page 113 SX-RX 50 Chassis Release the lock shown in the figure. Rear fairings - Remove the saddle - Remove the side fairing - Remove the four fixing screws indicated in the picture - Remove the screw under the mudguard, shown in the figure CHAS - 113...

  • Page 114: Rear Mudguard

    SX-RX 50 Chassis Air conveyor - To remove the air conveyor, take out the two screws indicated in the picture Rear mudguard - Remove the rear mudguard by loosening the 4 screws indicated in the figure Fuel tank - Remove the saddle - Remove the front half-fairings - Remove the mix oil tank - Remove the tank metal retaining strap by undo-...

  • Page 115: Front Mudguard

    SX-RX 50 Chassis - Slide the fuel tank off its seat Front mudguard - Remove the 4 screws shown in the figure, the transmission clamps and remove the mudguard Radiator fan Radiator fitting Radiator fitting - Mount the radiator following the removal procedure but in reverse order - Fill the tank with recommended coolant and make sure that the system does not leak Locking torques (N*m) Radiator clamps: 8 ÷...

  • Page 116: Expansion Tank

    SX-RX 50 Chassis Specific tooling 020544y Pliers for clamps Expansion tank - Remove Side fairings - Empty the expansion tank - Remove the two screws shown in the figure and the tank pipes - Remove the tank Mixture oil tank - Remove the saddle - Remove the rear fairings - Remove the oil intake pipes and empty the mixer...
  • Page 117 SX-RX 50 Chassis CHAS - 117...
  • Page 118 INDEX OF TOPICS PRE DE DELIVERY...
  • Page 119 SX-RX 50 Pre-delivery Carry out the listed checks before delivering the vehicle. WARNING BE EXTREMELY CAUTIOUS WHEN HANDLING FUEL. Aesthetic inspection - Paintwork - Fitting of Plastic Parts - Scratches - Dirt Scooter check - Paintwork - Fitting of plastic parts - Damages - Dirt Tightening torques inspection...
  • Page 120 SX-RX 50 Pre-delivery - Turn indicators and their warning lights - Instrument panel lights - Instrument panel: fuel and temperature indicator (if present) - Instrument panel warning lights - Horn - Electric start-up - Engine stop via emergency stop switch and side stand - Saddle electric opening switch (if present) - Through the diagnosis tool, check that the last mapping version is present in the control unit/s and, if required, program the control unit/s again: consult the technical service website to know about available...
  • Page 121 SX-RX 50 Pre-delivery - Rear light - Stop light (possibly front and rear brakes) - Turn indicators and the respective warning lights - Speedometer and instrument panel lighting - Horn - Starter button CAUTION TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE. INADEQUATE CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFORE IT IS FIRST USED SHORTENS THE LIFE OF THE BATTERY.

  • Page 122: Static Test

    SX-RX 50 Pre-delivery - Mixer oil level Road test - Cold start - Instrument panel operation - Response to throttle control - Stability when accelerating and braking - Front and rear brake efficiency - Front and rear suspension efficiency - Abnormal noise Test drive - Cold start - Speedometer operation check...

  • Page 123: Functional Inspection

    SX-RX 50 Pre-delivery CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE. REGU- LATE PRESSURE ACCORDING TO THE WEIGHT OF THE RIDER AND ACCESSORIES. CAUTION NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES AS THE TYRES MAY BURST. WARNING Be extremely cautious when handling fuel. Functional inspection - Hydraulic braking system - Brake levers stroke...
  • Page 124 Accessories: 40 Air filter: 21 Battery: 31, 37, 43, 44, 46, 116 Brake: 97–100, 103 Bulbs: Carburettor: 18, 82, 86 Coolant: 105 Fuel: 30, 82, 114 Fuses: 43 Gearbox oil: 26 Headlight: 26, 110 Horn: 39 Identification: 7 Maintenance: 17 Recommended products: Spark plug: 20 Tank: 114, 116...

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