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1. PERIODIC MAINTENANCE 2 1 6 MULTIFUNCTION DIGITAL COMPUTER C 364 Multifunction indicator functions Use the Mode button 2 on the LH handlebar to select among various functions clock setting odometer ODO trip meter TRIP battery voltage value and trip meter reset 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 the stored trip value Battery voltage With the odometer display press the Mode button 2 twice to display the battery function Conversion of unit of measurement Km Mi When the battery voltage is shown on the multifunction display 1 hold down the Mode button 2 for more than ten seconds to change the unit of measurement from kilometers Km to miles Mi While pressing the button the current unit of measurement will flash Should the button be pressed for less than ten seconds the conversion will not take place Setting the clock CAUTION For safety reasons it is possible to set this function only when the vehicle is stopped Hold down the Mode button 2 for at least three seconds The column dividing hours and minutes will start flashing Set the hour value it will increase by one unit every time you press the Mode button 2 Hold do
2. 3 2 11 TECHNICAL DATA M 3 2 1 2 SCHEDULED MAINTENANCE 5 2 1 3 LUBRICANT TABLE 6 244 TIGHTENING TORQUES erre ea eec 7 2 1 5 MULTIFUNCTION DIGITAL COMPUTER IE 361 IE 50 11 2 1 6 MULTIFUNCTION DIGITAL COMPUTER 364 18 2 2 SCHEDULED 19 2 2 1 BRAKE SYSTEM iiie beides 19 2 2 2 CLEANING THE AIR FIETER thc tte ei teen ecu tte tede rte tcr 23 2 2 3 COOLANT 24 2 24 GEAR FLUID IE361 C364 reete ttr ctetu 26 2 2 5 OEC 28 2 2 6 MIXER OUMESO1 C304 niei caus tes Fri een rente 30 2 2 7 MIXER OMNES OS 31 2 2 SR 50 2 1 SPECIFICATIONS 2 1 1 TECHNICAL DATA PERIODIC MAINTENANCE 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
3. Carburetor Idle E excluded speed n Transmission and control cables Drive belt Steering tube bearings and play Wheel bearings 1 1 Brake discs 1 Clamps Every 12000 km 7440 mi 1 Air filter Fuel filter Every 12000 km 7440 1 Throttle operation Vehicle operation Light system Stop light switch Braking systems brake discs Brake fluid check level 1 Brake fluid Every two years 3 Coolant Every 2000 Km 1240 mi 1 Every two years 3 Exhaust muffler exhaust silencer 1 Mixer throttle operation 1 1 Mixer oil Every 500 km 312 mi 1 Mixer oil DESI Every 2000 km 1240 mi 1 Front fork fluid and oil seal Every 12000 km 7440 mi 1 Every 12000 Km Rollers and guides of front converter Every 12000 km 7440 mi Gearbox oil 3 1 7440 mi or two years 3 Front pulley Every 12000 km 7440 mi 1 Injector cleaning GEES Every 16000 km 9920 mi 2 3 Wheels tires and inflating pressure 1 Wheels tires and inflating pressure Every month 1 Tightening of nuts and bolts 1 1 Tightening of battery clamps 1 Mixer oil reserve light 1 1 Fuel pipe Every 4000 Km 2500 mi 2 Every two years 3 Braking system lines Every 4000 Km 2500 1
4. Connect the starter motor positive cable to the relay Position the two ground cables tighten the screw SR 50 Connect the connector to the compressed air injector Connect the engine temperature sensor connector Connect the connector to the fuel injector Fasten the wiring with a new tie e Reposition the mixer 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 Position the cooling system hose onto the head Tighten the clamp SR 50 4 Connect the generator connector Fit the cooling system hose to the coolant pump Fasten the hose with the tie Fill and bleed air off the cooling system Connect the two mixer oil hoses WARNING Before using the vehicle bleed the mixer oil pump see MIXER OIL 1 361 C364 and MIXER OIL IE50 Place the two intake hoses the frame Fit the rear brake caliper 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 Fit the throttle body the fuel tank the battery the lower shield SR 50 SR 50 4 2 ENGINE IE 50 4 2 1 REMOVING THE ENGINE IE 50 To remove th
5. CYCLE PARTS CYCLE PARTS SR 50 5 1 2 REMOVING THE PASSENGER GRAB HANDLE Raise the seat Loosen and remove the four screws Remove the passenger grab handle 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 Loosen and remove the fourteen top screws Loosen and remove the four rear screws Loosen and remove the two lower screws CYCLE PARTS Disconnect the tail light connector Remove the tail guard together with the license plate holder SR 50 CYCLE PARTS SR 50 5 1 4 REMOVING THE LOWER SHIELD e Loosen and remove the three front screws E Working on either side loosen remove the rear Screw Loosen and remove the three top screws Remove the lower shield CYCLE PARTS SR 50 5 1 5 REMOVING THE FRONT COVER e Loosen 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 it from the right first then from the left 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
6. Wheelbase DESIT EEE 1260 mm 49 6 in Minimum ground clearance 100 mm 3 94 in Loadless weight in running order 108 kg 238 Ib ENGINE Type 2 strokes Model EEST C364M Model C361M Model Aprilia engine ditech Number of cylinders horizontal single cylinder Total displacement 49 38 3 01 in Bore stroke EEE 40 mm 39 3 mm 57 1 55 Bore stroke 41 mm 37 4 mm 1 61 in 1 47 Compression ratio EEE 12 1 0 5 1 Compression ratio 11 50 Compression ratio 12 50 Starting EEE electric kick starter Starting GE Electric starter Engine idling speed EEE 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 liters 12 7 pt Fuel reserve 1 2 liters 2 18 pt Gearbox oil 130 7 93 Gearbox oil E 75 cm 4 58 Mixer oil reserve included 1 2 liters 2 18 pt Mixer oil reserve 0 2 liters 0 36 pt Coolant 1 2 liters 2 18 pt 50 water 50 antifreeze with ethylene glycol Seats 1 2 in countries where a passenger is allowed Vehicle max l
7. Do not drive the vehicle if the brakes are worn or not operating correctly The brakes are the vehicle s most important safety component and using the vehicle with the brakes in less than perfect operating condition comprises a high probability of traffic accident which can result in serious injury or death The brakes are significantly less effective on a wet road surface DANGER If the road surface is wet maintain a double braking distance as both the brakes and the grip of the tires are significantly less effective in such conditions Water on brakes whether due to a recent wash or picked up from a wet road surface puddles or drains can result in significantly reduced brake efficiency Failure to observe these instructions can result in serious accidents with the risk of serious personal injury or death The brakes are essential to your safety Do not drive the vehicle if the brakes on not in perfect operating condition Always check the brakes before riding the motorcycle 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 the eyes contact an eye specialist or seek medical attention DO NOT DISPOSE OF BRAKE FLUID IN THE ENVIRONMENT KEEP AWAY FROM CHILDREN Avoid spillage Brake fluid can damage plastic or painted parts DANGER Do not use brake fluids other than the specified type Never mix different typ
8. Wheelhouse support to frame fastener 2 Screw M6x16 10 20 Coil to connection plate fastener 2 Screw 4 20 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 21 Connecting to frame connecting rod to engine fastener ae mae 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 Steering nut fastener 1 Nut M32x1 10 20 Steering lock nut 1 Self locking nut M32x1 110 m Rear suspension Shock absorber lower screw fastener 1 Screw M10x55 40 20 Shock absorber upper screw fastener 1 Screw M10x35 50 20 Cover to crankcase cover fastener 4 Self tapping 3 9x14 plastic 0 5 Inner disc to crankcase cover fastener 3 Self tapping 3 9x14 plastic 0 5 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 40 20 fastener Engine Converter unit cover fastener Self tapping screw M5 20 Allen cheese headed Converter cover to crankcase fastener screw 2 10 20 Filter box Air box to bracket f
9. Every two years Mixer oil pipe 1 1 every two years 3 Front and rear brake wear 1 Every 2000 km 1240 mi 1 Clutch wear 1 clean replace adjust 1 2 3 4 check and clean adjust lubricate or change if necessary Carry out the maintenance operations more frequently if you use the vehicle in rainy and dusty areas or on uneven ground OPERATIONS THAT CAN BE CARRIED OUT BY THE USER PERIODIC MAINTENANCE SR 50 2 1 3 LUBRICANT TABLE LUBRICANT PRODUCT Gearbox oil RECOMMENDED F C SAE 75W 90 or GEAR SYNTH SAE 75W 90 As an alternative to recommended oil top brand oils meeting or exceeding A P l GL 4 specifications can be used Mixer oil RECOMMENDED PROGPX2 or GREEN HIT 2 as an alternative Agip CITY 2T As an alternative to recommended fluids top brand oils meeting or exceeding SJ specifications can be used Front fork fluid RECOMMENDED 5w or F A 20w as an alternative 8 FORK E amp gip FORK 20W When you wish to obtain an intermediate response between those offered by 5W and 20w V Agip FORK 5W FORK 20W you may mix the different products as follows SAE 10W F A 5W 67 of volume E F A 20W 33 of volume of volume o of volume FORK 5W 67 of vol FORK 20W 33 of vol SAE 15W 5W 33 of volume
10. CHILDREN OBJECTS IN MIRROR ARE CLOSER THAN THEY APPEAR Never insta accessories ar replacement parts nol approved by Aprilia as orginal equipment This can degrade the handling and safety af your moforeyel and wh subsequent accident amd serious injury or even death The atshilify and safety of any motoreyele adversely affected by the of any camping accessory See awner s manual 10 WARNING DO NOT REMOVE THE CAP UNTIL THE ENGINE SEALED CIRCUITS USE ONLY ANTIFREEZE AND ANTICORAOSIVE WITHOUT NITRATE ENSURING PROTECTION 35 C AT LEAST GENERAL INFORMATION 11 SR 50 T MOTORCYCLE NOISE EMISSION CONTROL INFORMATION THIS 2206 ASP21E00 8 MOTORC TELE B 1115 MEETS NOISE EMISSION REQUIREMENTS OF 70 dili Muffler stamping ATTENTION STARTING PROCEDURE Set on brakes and push START button See owner s manual GENERAL INFORMATION SR 50 15 USARE BENZINA SENZA PIOMBO N O min 85 USE UNLEADED FUEL RON 85 16 WARNING Do not modify or tamper with this engine control unit in way Modifications to this unit may reduce performance and are prohibited by state and Federal laws Any modification of this unit will immediately void the warranty SR 50 PERIODIC MAINTENANCE PERIODIC MAINTENANCE 2 PERIODIC MAINTENANCE SR 50 TABLE OF CONTENTS 2 1 SPECIFICATIONS e
11. E F A 20W 67 of volume FORK 5W 33 of volume Agi FORK 20W 67 of volume Bearings and other lubrication points RECOMMENDED Lil AUTOGREASE MP or V GREASE 30 As an alternative to recommended grease use top brand roller bearing grease that will resist a temperature range of 30 C 22 F to 140 C 284 F with dropping point 150 C 302 F to 230 C 446 F high corrosion protection good resistance to water and oxidization Battery terminals Use neutral grease or Vaseline Brake fluid CAUTION Use new brake fluid only Do not mix different makes or types of oil without having checked bases compatibility The braking system is filled with DOT 4 FLUID compatible DOT 5 As an alternative to the recommended product top brand brake fluid meeting or exceeding SAE J1703 NHTSA 116 DOT 4 ISO 4925 specifications for synthetic brake fluid can be used Engine coolant CAUTION Use only nitrite free antifreeze and corrosion inhibitors with a freezing point of 35 C 31 F as a minimum RECOMMENDED Ell ECOBLU 40 or QM COOL SR 50 2 1 4 TIGHTENING TORQUES WARNING PERIODIC MAINTENANCE The fastening elements listed should be tightened to the specified torque using a torque wrench and applying LOCTITE where indicated
12. and extract the plug dipstick Clean the part in contact with the oil with a clean cloth Tighten the plug dipstick fully into the filler opening Extract the plug dipstick again and check the oil level on the dipstick The correct level is achieved when the oil reaches approximately the second mark over the dot If necessary top up TOPPING UP Pour small quantity of oil into the filler opening Allow one minute for the oil to flow into the crankcase Check the oil level and top up if necessary Top up by adding small quantities of oil until reaching the prescribed level When finished tighten the plug dipstick CAUTION Do not use the vehicle when lubricant levels are low or the lubricant has become contaminated Use specified lubricants only Improper lubrication will lead to moving part fretting resulting in irreparable damage 2 26 SR 50 PERIODIC MAINTENANCE SR 50 CHANGE Position the vehicle on firm and level ground Position the vehicle on the center 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 cool down Unscrew extract the plug dipstick Take a receptacle of suitable capacity and set it under the drain screw Release remove the drain screw Let fluid fully drain inside the container WARNING Us
13. and refit them in their housings Wash blow the filter with compressed air SR 50 a SR 50 CYCLE PARTS CYCLE PARTS CYCLE PARTS SR 50 TABLE OF CONTENTS 5 1 eld eue illc M 3 5 1 1 REMOVING THE 3 5 1 2 REMOVING THE PASSENGER GRAB 4 5 1 3 REMOVING THE TAIL 5 5 1 4 REMOVING THE LOWER sises EE tate a En SERA Ea nE 7 5 1 5 REMOVING THE FRONT COVER 8 5 1 6 REMOVING THE FRONT 9 5 1 7 REMOVING THE REAR MUDGUARD 5 ettet etate tante tha tik erini na Ra ada a sane 10 5 1 8 REMOVING THE TOOL KIT nennen eh 11 5 1 9 REMOVING THE INNER SHIELD ttti trai etae Ehe niente etna 12 5 1 10 REMOVING THE FIEADLIGE ete ere tnt en ricus 14 5 1 11 REMOVING THE FRONT 16 5 1 12 REMOVING THE INSTRUMENT PANEL essere 17 5 2 EXHAUST SYSTEM EMT rm 19 5 2 1 REMOVING THE EXHAUST SYSTEM IE361 364 19 5 2 REMOVING THE EXHAUST 5
14. aprilia com www serviceaprilia com INTRODUCTION 0 1 2 REFERENCE MANUALS SPARE PARTS CATALOGUES Version 5564 00 T O UU Version TE aprilia part descripion 5574 00 og O gt OWNER S MANUALS 8202397 ale 8202441 O gt 8202442 8202439 e Cc ENGINE WORKSHOP MANUAL Engines 8140818 T 8140821 8140819 gt 8140820 8140822 8 0067 T O C ENGINE WORKSHOP MANUAL Engines 8140645 8140646 8140647 8140648 8140649 8 006 P CHASSIS WORKSHOP MANUAL 8140812 8140815 8140813 8140814 8140816 8140817 8CM0064 8 0065 1 A SR 50 SR 50 AVIDC bar DC cc DIN DOHC ECU rpm HC ISC ISO kg kgm km km h 5 kW LED LEFT SIDE m s max mbar mi MIN MPH MS MO N A N O M M N O R M Nm Q PICK UP BDC TDC PPC RIGHT SIDE SAE SAS number is less than js more than is less than or equal to more than or equal to approximately infinite degrees Celsius centigrade degrees Fahrenheit plus or minus Alternated Current Ampere Ampere per hour American Petroleum Institute High Tension ABBREVIATIONS SYMBOLS CONVENTIONS Anti Vibrati
15. drain the cooling system Using belt and an A frame lift the vehicle rear end Loosen and remove the shock absorber upper screw Loosen and remove the two cable guide screws Loosen and remove the two screws Slide out the rear brake caliper keep it connected to the fluid line 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 hoses Fold the lines and tie them Remove the cooling system hose from the head Disconnect the spark plug 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 Disconnect the compressed air injector connector Loosen the screw remove the two ground cables Disconnect the starter motor positive cable from the relay end Remove the clamp SR 50 SR 50 Working on the right side loosen and remove the nut Working on the left side remove the pin Remove the 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
16. for a certain time DIAGNOSTICS sub menu this menu allows you to perform diagnosis and service operations 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 Authorized 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 view any current errors active or stored memo as detected by the ECU The presence of an error is indicated by To identify the error please refer to the ECU error codes table PERIODIC MAINTENANCE EA PERIODIC MAINTENANCE SR 50 ERROR DESCRIPTION ECU ERROR CODE Engine overheat ECU 01 Pick up sensor failure ECU 02 Wrong signal from throttle position sensors ECU 03 Wrong signal from throttle position sensor 1 ECU 04 Wrong signal from throttle position sensor 2 ECU 05 Throttle position sensor 1 malfunction ECU 06 Throttle position sensor 2 malfunction ECU 07 Throttle position sensors malfunction ECU 08 Incorrect charging voltage ECU 09 Oil pump malfunction ECU 10 Air injector malfunction ECU 11 Fuel injector malfunction ECU 12 Ignition circuit malfunction ECU 13 Fuel pump malfunction ECU 14 Engine rpm limiter tripped ECU 15 Error in ECU power supply ECU 16 Rpm limit
17. for a longer period Multifunction indicator functions Move the UP DOWN joystick to display the sequence of the various functions TRIP 1 gt TRIP 2 gt BATTERY VOLTAGE gt CHRONOMETER MENU T TRIP1 TRIP2 functions The two pages display two stored values for trip meter average speed maximum speed The values can be reset by holding down the MODE joystick for a certain time Battery Voltage function Battery voltage is displayed PERIODIC MAINTENANCE 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 the current measure is cancelled and a new one is started If the MODE joystick is pressed after 10 seconds have elapsed since chronometer start the current measure is stopped stored and a new one is started Hold down the 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 the MODE joystick again to access the SETTINGS CHRONOMETER DIAGNOSTICS LANGUAGE sub menus SETTINGS sub menu this menu allows Time setting from the SETTINGS menu briefly press the MODE joystick to enter the setting function Set the time
18. fuel sensor connector Loosen and remove the two screws Disconnect breather pipe from frame end CAUTION Place some paper under the coupling to collect any fuel spillage e Disconnect the fuel delivery lines 1 and vacuum lines 2 e Fold the delivery line 1 on itself and tie FUEL SYSTEM Loosen and remove the two screws Release the seat release cable on the tank end Remove the fuel tank together with helmet compartment SR 50 FUEL SYSTEM SR 50 DO U U ______ ___ _ ___ __ 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 counterclockwise Remove the fuel sensor FUEL SYSTEM SR 50 3 2 AIRFILTER 3 2 1 REMOVING THE AIR FILTER AND THE AIR BOX IE361 IE50 REMOVING THE AIR FILTER IE 361 IE 50 Loosen and remove the three screws e Loosen and remove the two screws collect the washers and the spacers Move the cover aside do not disconnect the air intake line SR 50 Remove the air filter REMOVING THE AIR BOX IE 361 IE 50 e Loosen and remove the two screws collect the washers and the spacers Loosen and remove the rear mudguard screw Disconnect the air intake line Loosen the clamp and remove the throttle body intake hose Remove the air box FUEL SYSTEM FUEL SYSTEM 3 2 2 REMOVING THE AIR FILTER AND THE AIR
19. in place or the caliper piston might come off its housing thus causing brake fluid leakage SR 50 SR 50 5 4 5 4 1 REAR WHEEL REAR WHEEL DIAGRAM CYCLE PARTS Key o O0 qub o No Tire Bare rear wheel Brake disc Tubeless valve Pads Rear brake caliper Air bleed Rear brake line Rear wheel nut Rear wheel plate Ring Pin caliper sprin Bare rear hub Split pin Cap CYCLE PARTS SR 50 5 4 2 REMOVING THE REAR WHEEL Position the vehicle the center stand Set a support under the frame Remove the exhaust system see REMOVING THE EXHAUST SILENCER Loosen remove the two screws Slide out the rear brake caliper keep it connected to the fluid line Remove the cover Remove the split pin on the wheel shaft Remove the nut cover Loosen and remove the wheel shaft nut Remove the rear wheel together with brake disc slide it out from the right side WARNING Do not operate the front brake lever when the wheel is not in place or the caliper piston might come off its housing thus causing brake fluid leakage CYCLE PARTS SR 50 JEN cu 5 5 BRAKING SYSTEM 5 5 1 CHANGING THE BRAKE PADS Position the vehicle on the center stand Remove the brake caliper from the disc but leave the line connected For the front brake caliper only Remove the brake caliper cover WARNING Be careful not to damage the rim paint during removal and reassembl
20. injury or death Prolonged or repeated contact with gear fluid may cause severe skin damage Wash your hands thoroughly after handling Do not dispose oil in the environment For disposal contact the nearest waste oil reclamation firm or the supplier A WARNING Avoid spillage when filling the vehicle with oil Immediately clean up any spilt oil which can damage painted parts Oil on the tires can make them very slippery and dangerous to use In case of oil leaks do not use the motorcycle Identify the cause of the leak and repair it ENGINE OIL DANGER Prolonged or repeated contact with engine oil may cause severe skin damage Wash your hands thoroughly after handling Do not dispose oil in the environment For disposal contact the nearest waste oil reclamation firm or the supplier Wear latex gloves during servicing FRONT FORK FLUID 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 is SAE 20 W Choose suitable viscosity grades according to the desired set up SAE 5W softer 20W stiffer The two grades can also be mixed in varying solutions to obtain the desired response SR 50 GENERAL INFORMATION BRAKE FLUID CAUTION This vehicle is fitted with front and rear disc brakes Each brake system is operated by an independent hydraulic circuit The information provided below applies to both brake systems DANGER
21. of the motorcycle potentially resulting in serious injury or death 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 Refueling and maintenance operations should be carried out in a well ventilated area with the engine off Do not smoke when refueling or in the proximity of sources of fuel vapors Avoid contact with bare flames sources of sparks or any other source which may ignite the fuel or lead to explosion Take care not to spill fuel out of the filler as 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 with heat and when left under direct sunlight Never fill the fuel tank up to the rim Tighten the filler cap securely after each refueling Avoid contact with the skin and the inhalation of vapors do not swallow fuel or pour it from a receptacle into another by means of a tube DO NOT DISPOSE OF FUEL IN THE ENVIRONMENT KEEP AWAY FROM CHILDREN Use only unleaded gasoline with a minimum octane rating of 95 RON and 85 MON LUBRICANTS DANGER Correct lubrication is essential to the safety of the motorcycle Failure to maintain the lubricant level or the use of incorrect old or dirty lubricant can cause the engine or transmission to seize resulting in accident serious
22. screw Fill the cooling system SR 50 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 ENGINE 4 27 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 SR 50 Connect the temperature sensor Fit the spark plug cap Install the exhaust Install the two rear side panels Install the carburetor Fit the hose to the mixer pump Fit the clamp Pinch the hose delivery Fit the mixer pump drive cable Fit the converter cover Fit and tighten the fifteen screws Fit the rear brake caliper Fit the air box hose ENGINE 4 29 SR 50 4 4 SECONDARY AIR SYSTEM 4 4 1 SECONDARY AIR SYSTEM SYSTEM DIAGRAM Key 1 2 3 4 Intake manifold Secondary air valve From the engine Exhaust SR 50 SAS 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 stream to trigger a post combustion process that raises the temperature of the exhaust gas
23. see REMOVING THE FRONT WHEEL Remove the front mudguard see REMOVING THE FRONT MUDGUARD Loosen and remove the two inner screws Release the wheelhouse cover and slide it out of the fork Completely turn the handlebar to the side of the fork leg to be removed Loosen the plate clamp screw Slide out and raise the fork leg as much as necessary to be able to remove the snap ring Move down the fork leg with the wheel holder and remove it completely CYCLE PARTS SR 50 5 7 3 DISASSEMBLING THE STANCHION Remove the stanchion assembly see REMOVING THE FORK LEG CAUTION Prepare a graduated receptacle with a capacity of at least 300 cm 18 31 Let the fork leg enter the stanchion completely turn the stanchion assembly and let the fluid drain in the container WARNING Check the oil level If lower than 103 cm 6 28 top up or change Loosen and remove the screw 1 bottom end collect the copper washer 2 Slide out the slider 3 with damper 4 Turn the stanchion 5 collect the buffer 6 and the counter spring 7 Remove the dust seal 8 Remove the 9 WARNING While reassembling fit the circlip 9 with the sharp edge fully home see figure Remove the seal 10 SR 50 5 8 REAR SUSPENSION 5 8 1 REMOVING THE SHOCK ABSORBER Position the vehicle on the center stand A WARNING Fit a suitable shim
24. the spark plug Disconnect the temperature sensor connector Remove the two rear side panels see REMOVING THE REAR SIDE PANELS Remove the exhaust see REMOVING THE EXHAUST Disconnect the alternator connector Loosen and remove the four screws Remove the tie and the cover SR 50 Loosen and remove the two upper screws securing the lower cover Loosen 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 Remove the clamp E Disconnect the connector Loosen 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 Remove the rear shock absorber lower screw see REMOVING THE REAR SHOCK ABSORBER Working on the right side loosen and remove the nut SR 50 Working the opposite side remove the pin Remove the engine a 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 Fit a new clamp tighten Fit and tighten the drain
25. to frame and to helmet 4 Allen cheese headede 10 20 holder fastener screw M6x25 mdi Allen crowned head Helmet compartment to frame fastener 2 screw 6 16 7 20 Allen crowned head Rear mudguard to air box fastener 1 screw 5 16 with collar 2 20 Rear cat s eye to license plate holder 2 Nut M14 fastener Locks Seat latch to inner shield fastener 2 Allen crowned head 2 20 screw M5x16 Levers to helmet compartment 2 Allen crowned head 20 fastener screw M6x16 d Lock to tunnel cover fastener 1 Narrow head nut M19x1 4 Lever to tunnel cover lock fastener 1 4 6 3 20 i Allen cheese headed Ignition lock to frame fastener 1 screw M6x16 10 20 Seat Seat bottom end to frame fastener Self tapping 5x14 plastic 1 5 Box to lug fastener Self tapping 3 9x14 0 7 plastic Box to lug fastener 2 Self tapping 3 9x14 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 MEJ 3 M5x16 5 20 Coil connection plate to frame fastener 1 M6x12 10 20 ae Crown cheese headed Tail light glass fastener 1 screw 5 10 1 PERIODIC MAINTENANCE SR 50 Description Q ty Type of fastener TEM Tol Note Instrument panel Steering head Instrument panel to support plate 3 Self tapping 5x14 plastic 0 5 _ fasten
26. using the UP DOWN joystick confirm it with the MODE joystick Using the UP DOWN joystick shift to minutes confirm the set value with the MODE joystick Code change from the SETTINGS menu shortly press on the MODE joystick to enter the function for setting the 5 digit safety code Set the first digit using the UP DOWN joystick confirm it with the MODE joystick Then set the following digit CAUTION The safety code will be necessary to start the vehicle with a key that is not fitted with a transponder or in any case not initialized on the vehicle The safety code stored on any new vehicle is 00000 Every time a new vehicle is started the instrument panel displays a warning prompting the rider to customize the safety code We recoomend you set the standard code with your personal one take note of the new code and keep it in a safe place not on the scooter itself and remember to give it to the new owner in case of sale CRONOMETRO DIAGNWOSTICA LINGUE ESCI IMPOSTAZION REGOLAZIONE OHA MODIFICA CODE ESLI IMPOSTAZION REGOLAZIONE ORA MODIFICA CODE ESCI SR 50 SR 50 CHRONOMETER sub menu this menu allows DISPLAY enter this menu to display the times recorded using the Chronometer function Briefly press the MODE joystick to quit time display mode DELETE enter this menu to delete the times recorded using the Chronometer function All values can be deleted by holding down the MODE joystick
27. 0 22 45 40 40 55 CAUTION Coolants have varying specifications The degree of protection is written on the label WARNING Use only nitrite free antifreeze and corrosion inhibitors with a freezing point of 35 C 31 F as a minimum TIRES A WARNING An over inflated tire results in a hard uncomfortable and less secure ride Over inflation also affects grip especially on curves and wet surfaces An under inflated tire insufficient pressure can slip on the wheel rim resulting in loss of control Under inflation also affects grip and handling as well as braking efficiency Tire replacement and repair and wheel servicing and balancing are delicate operations They should be carried out using adequate tools and are best left to experienced mechanics New tires may be covered with a thin layer of protective coating which is slippery Drive carefully for the first few kilometers miles Never use any kind of rubber treatment product on the tires particular do not allow the tire to come in contact with liquid fuel which rapidly deteriorates the tire rubber In case of contact with oil or fuel do not clean but replace the tire DANGER Some of the factory assembled tires on this vehicle are equipped with wear indicators There are various types of wear indicators For more information on how to check wear contact your Dealer Check the wear visually and have the tires replaced when they are worn If a tire deflates duri
28. 1229 5 SR 50 00 2005 05 o 15 5 9 g workshopmanual 8140817 SR 50 INTRODUCTION INTRODUCTION INTRODUCTION SR 50 TABLE OF CONTENTS sli aio M 3 Dd du E MEE EE 3 0 1 2 REFERENCE MANUALS icc iu opea iui ueste 4 0 1 3 ABBREVIATIONS SYMBOLS CONVENTIONS 5 INTRODUCTION SR 50 0 1 FOREWORD 0 1 1 FOREWORD This manual provides the information required for normal servicing This manual is intended for use by aprilia Dealers and their qualified mechanics certain information has been omitted intentionally as this manual does not purport to provide a comprehensive treatise on mechanics The persons who will use this manual must be fully conversant with the basics of mechanics and with the basic procedures of motorcycle repair Repairing or inspecting a motorcycle when one does not possess such basic knowledge or training could result in improper servicing and make the motorcycle unsafe to ride For the same reason certain basic precautions have been omitted in the descriptions of repair and inspection procedures you are therefore invited to take special care to avoid damage to motorcycle components or injury to persons aprilia s p a s mission is to constantly enhance the riding pleasure of final users through the ongoing
29. 5 50 20 5 3 FRONT WHEEL 21 5 3 1 FRONT WHEEL DIAGRAM tutte EF Dna ee dx Rr RENTES 21 5 3 2 REMOVING THE FRONT entier 22 5 4 REAR WHEEL 23 5 4 1 REAR WHEEL DIAGRAM M 23 5 4 2 REMOVING THE REAR WEEEL 1 1 eo testet 24 5 5 BRAKING x 25 5 5 1 CHANGING THE BRAKE PADS 25 5 6 27 5 6 1 2 55522 27 5 7 nien aol 28 5 7 1 FRONT FORK DIAGRAM mC 28 5 7 2 REMOVING THE FORK LEG 29 5 7 3 DISASSEMBLING THE 5 ee 30 5 8 REAR SUSPENSION tine 31 5 8 1 REMOVING THE SHOCK 31 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
30. 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 Partially remove the air box cover 3 Remove the mesh 5 Remove the filter 6 REMOVING THE AIR BOX C364 Loosen and remove the two screws 2 collect the washers Loosen the tie 7 Disconnect the air intake line Loosen the clamp 8 and remove the carburetor intake hose the air box SR 50 FUEL SYSTEM SR 50 3 3 INJECTION UNIT 3 3 1 INJECTION SYSTEM DIAGRAM 50 ETT oir T p i A S Fuel tank Fuel pump Oil reservoir Oil pump ECU Coil Air intake Air compressor Throttle body 10 Pressure regulator 11 Fuel injector 12 Direct injector FUEL SYSTEM SR 50 3 3 2 REMOVING THE THROTTLE BODY IE361 50 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 CAUTION If the throttle body is to be completely removed disconnect it from the throttle cable FUEL SYSTEM SR 50 52 44 3 3 3 REMOVING THE INJECTION UNIT IE361 IE50 Move the fuel tank aside keep it connected to the seat r
31. M Key O 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 Fuel return hose Breather hose High pressure fuel from injection unit Low pressure fuel from injection unit FUEL SYSTEM SR 50 3 1 2 FUEL SUPPLY SYSTEM DIAGRAM C364 1 Fueltank 2 Fuellevel sensor 3 Fuel collection rubber element 4 Overflow line 5 Breather hose 6 Vacuum fuel cock 7 Fuel hose 8 Vacuum hose FUEL SYSTEM SR 50 E UEM 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 Loosen and remove the two screws Disconnect the fuel pump connector Move the tank aside to remove the breather line from the frame Disconnect the two quick release fittings on the injection unit FUEL SYSTEM SR 50 Loosen and remove the two screws collect the spacers Release the seat release cable on the tank end Remove the fuel tank together with helmet compartment FUEL SYSTEM SR 50 54 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
32. OF CONTENTS 1 1 STRUCTURE OF THE MANUAL itte rr re terr ette t che te ee reip 3 1 1 1 CONVENTIONS USED IN THE 04 3 1 1 2 SAFETY zuo cm 4 1 2 GENERAL RULES rarus cre 5 1 2 1 AWlezJdadiillBcc 5 1 3 DANGEROUS ELEMENTS ren t rct ta e repere orte eben 8 1 38 12 WARNINGS me 8 1 4 11 1 4 1 tert endete a set Nt EE 11 1 5 12 1 5 1 POSITION OF THE SERIAL 12 1 6 POSITION OF THE ADHESIVE 5 13 1 6 1 POSITION OF THE ADHESIVE WARNING LABELS sse nennen nnns 13 GENERAL INFORMATION SR 50 1 1 STRUCTURE OF THE MANUAL 1 1 1 CONVENTIONS USED IN THE MANUAL e This manual is divided in sections and subsections each covering a set of the most significant components For quick reference see the summary of sections e Unless expressly specified otherwise assemblies are reassembled by reversing the disassembly procedure e The terms left and right are referred to the motorcycle when viewed from the riding position e Motorcycle operation and basic mai
33. SR 50 ELECTRICAL SYSTEM ELECTRICAL SYSTEM ELECTRICAL SYSTEM SR 50 TABLE OF CONTENTS 7 1 CHECKING THE ELECTRICAL 3 7 1 1 CHECKING THE COMPONENTS E360 1i nette erit etn terere bn dne EEES 3 7 1 2 CHECKING THE COMPONENTS IE5Q aeterne tentant 7 7 1 3 CHECKING THE COMPONENTS 364 11 7 2 WIRING SYSTEM 5 teneas hn Fan teet FEL a Eran 14 7 2 4 WIRING DIAGRAM IE 361 Glass ete ete easier nea Eee 14 7 2 2 WIRING DIAGRAM IE 50 16 7 05 WIRING DIAGRAM Q 3064 eet 18 ELECTRICAL SYSTEM SR 50 7 1 CHECKING THE ELECTRICAL COMPONENTS 7 1 1 CHECKING THE COMPONENTS 1 361 1 Generator three phase generator winding resistance 1 ohm output voltage 50AC to be measured with the generator disconnected from wiring system and the engine at 3000 rpm 2 Rpm sensor inductive sensor winding resistance 110 ohms ELECTRICAL SYSTEM 3 Starter motor current absorbed in operation 20 A 4 Fuel pump absorption 0 35 A 5 Tail light parking stop light 12V 5 21W 6 Ignition coil primary resistance 0 7 ohms SR 50 ELECTRICAL SYSTEM SR 50 7 Fuel sensor resistance across terminals 1 and 3 5 ohms with full f
34. WER 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 Remove the exhaust system CYCLE PARTS CYCLE PARTS SR 50 5 2 2 REMOVING THE EXHAUST SYSTEM 50 Loosen 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 Raise the mudguard Loosen and remove the screw 5 securing the silencer to the engine Remove the silencer SR 50 5 3 5 3 1 WHEEL FRONT WHEEL DIAGRAM CYCLE PARTS Key Front wheel rim Bearing Inner spacer Left spacer Wheel shaft Tubeless valve Brake disc Brake disc screws Tire Drive Drive seal Odometer drive fitting Washer Nut CYCLE PARTS 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 center stand Set a support under the frame Remove the brake caliper see CHANGING THE FRONT AND REAR BRAKE PADS Loosen remove the wheel shaft nut Loosen the shaft screws Loosen and remove the wheel shaft Collect the odometer drive fitting Slide out the wheel WARNING Do not operate the front brake lever when the wheel is not
35. YSTEM SR 50 7 1 3 CHECKING THE COMPONENTS C364 1 Generator two phase generator winding resistance 0 5 1 ohms 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 ohms ELECTRICAL SYSTEM 3 Starter motor absorption in operation 20 A 4 Tail lights parking stop light 12V 5 21W 5 Fuel sensor resistance measure across pin 1 and 2 5 ohms with full fuel tank 38 ohms with half full fuel tank 100 ohms with empty fuel tank 6 Fuses 7 5A fuse 1 From ignition switch to Instrument panel key operated power Stoplights Mixer oil reserve sensor Fuel sensor Coolant temperature sensor Turn indicator circuit Diagnostics circuit 15A fuse 2 From battery to Rectification charge circuit Ignition switch Positive permanent on instrument panel SR 50 SR 50 7 Headlight low beam 12V 35 high beam 12 35 8 Engine temperature sensor NTC sensor resistance 560 ohms at 25 resistance 40 ohms at 100 ELECTRICAL SYSTEM ELECTRICAL SYSTEM SR 50 7 2 WIRING SYSTEM DIAGRAMS WIRING DIAGRAM IE 361 7 2 1 7 14 SR 50 OCONDARWN gt Multiple connectors Low High beam relay Oil level switch Fuel level sensor Instrument panel matrix Immobilizer antenna Key
36. anifold Loosen remove the screw remove the throttle cable with gate SR 50 SR 50 5 4 1 3 4 1 1 36 25 3 4 12 INSTALLING THE ENGINE 369 tercero teet haeret srt et rna exe 8 4 2 ENGINEIE 50 faces sats enirn ect Dn 13 4 2 1 REMOVING THE ENGINE IE 50 13 4 2 2 INSTALLING THE ENGINE IE 50 eter oit 17 4 3 36 c 21 4 3 1 REMOVING THE ENGINE 304 eres ient te etra ttr eta aoreet e EE Ha a rne dace ipie 21 4 3 2 INSTALLING THE ENGINE 364 26 4 4 SECONDARY E 30 4 4 1 SECONDARY AIR SYSTEM etti Aaa AEE 30 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
37. ary top up with mixer as described above SR 50 FUEL SYSTEM FUEL SYSTEM FUEL SYSTEM SR 50 TABLE OF CONTENTS 3 1 FUEL TANK de HE 3 3 1 1 FUEL FEED SYSTEM DIAGRAM IE361 1 50 2 0401 0 3 3 1 2 FUEL SUPPLY SYSTEM DIAGRAM 364 4 3 1 3 REMOVING THE FUEL TANK E361 IE5O ttt teret tne 5 3 1 4 REMOVING THE FUEL TANK C364 inei eter Di Pate Las trea tete aca 7 3 1 5 REMOVING THE FUEL SENSOR 9 3 2 10 3 2 1 REMOVING THE AIR FILTER AND THE AIR BOX IE361 1 50 40 42222222 10 3 22 REMOVING THE AIR FILTER AND THE AIR BOX 364 2 0 12 3 3 2 5 5 13 3 3 1 INJECTION SYSTEM DIAGRAM 1 50 4 13 3 3 2 REMOVING THE THROTTLE BODY IE361 IE5O 2 14 3 3 3 REMOVING THE INJECTION UNIT 1E361 1 50 15 3 4 CARBURETOR 4 iante 16 3 4 1 CARBURETOR DIAGRAM C364 22 16 3 4 2 REMOVING THE CARBURETOR 364 17 SR 50 3 1 FUEL TANK 3 1 1 FUEL FEED SYSTEM DIAGRAM IE361 IE50 FUEL SYSTE
38. astener 2 M6x60 10 20 fe bracket to engine fastener 1 6 40 10 20 fe bracket to engine fastener 1 M6x30 40 20 Base cover fastener 3 Self tapping 5x20 plastic 2 to cover fastener EI 4 Self tapping 3 9x14 plastic 0 8 Hose tie to base fastener 1 Tie 25 45 0 4 Hose tie to throttle body fastener 1 Tie 25 45 2 PERIODIC MAINTENANCE SR 50 crown cheese headed 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 8 85 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 screw M8x30 25 10 Wheel shaft fastener 1 Nut M12x1 25 50 10 Wheel shaft clamp fastener 2 Screw M6 10 10 Rear Wheel EEZIZET Allen crowned head Brake disc fastener 3 screw M8x25 25 10 Allen cheese headed Wheel hub fastener 3 screw M10x55 50 20 Hub to engine fastener 1 Nut M16 130 10 Rear wheel LEJ Wheel to engine fastener 1 M14x1 5 110 10 Front and rear brake Hex head screw flandrin Front brake caliper fastener 2 M 8x35 27 10 Allen crowned head Rea
39. bleed valve Loosen the bleed valve again by about half a turn Check that the fluid comes out of the plastic tubing and as soon as the fluid color changes from a darker to a lighter color tighten the bleed valve and remove the tubing Refit the rubber cap Top up fluid inside the reservoir SR 50 PERIODIC MAINTENANCE SR 50 DDD ee CHECKING 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 center stand Using lamp and mirror placed between the brake caliper and pads visually check as follows FRONT BRAKE CALIPER From below on the front part for the left pad From above on the front part for the right pad look through the rim REAR BRAKE CALIPER From above on the rear for both pads If the thickness of the friction material even of a single pad has reduced to about 1 5 mm 0 05 in have both pads changed Front brake pads 4 Rear brake pads 5 PERIODIC MAINTENANCE BLEEDING THE BRAKING SYSTEM Any air present inside the hydraulic circuit will serve as a pad by absorbing most of the pressure coming from the brake master cylinder thus reducing caliper efficiency during braking If air is present inside the circuit the brake control is spongy and braking efficiency is reduced DANGER It is essential to bleed air
40. cle with insufficient lubrication or with contaminated or unsuitable lubricants since this would cause early wear of moving parts and may also cause irreparable damage CHANGE Ride several miles to warm up the engine to operating temperature and then stop the engine Position the vehicle on the center stand Place a graduated receptacle 1 with at least 150 cm capacity 9 15 in under the drain plug 2 PERIODIC MAINTENANCE SR 50 Unscrew remove the filler plug 3 and drain plug 2 Let the oil fully drain off the crankcase Tighten the drain plug 2 and pour through the filler 130 cm 7 93 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 moving parts and may also cause irreparable damage PERIODIC MAINTENANCE SR 50 2 2 6 MIXER OIL IE361 C364 TOPPING UP CAUTION The vehicle fits a separate mixer that mixes fuel and oil necessary for lubrication Remove the front cover see REMOVING THE FRONT COVER Remove the plug Fill with oil see LUBRICANT CHART Refit the plug AIR BLEED WARNING If the oil in the mixer oil reservoir is
41. ding resistance 110 ohms ELECTRICAL SYSTEM 3 Starter motor current absorbed in operation 20 A 4 Fuel pump absorption 0 35 A 5 Tail lights parking stop light 12V 5 21W 6 Ignition coil primary resistance 0 7 ohms SR 50 SR 50 7 Fuel sensor resistance across terminals 1 and 3 5 ohms with full fuel tank 88 ohms with half full fuel tank 100 ohms 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 Turmindicators 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 35 low high beam 12V 35W ELECTRICAL SYSTEM ELECTRICAL SYSTEM 11 Throttle body FUEL INJECTOR winding resistance 1 7 ohms THROTTLE POSITION SENSOR TPS resistance across terminals 1 and 4 1 1 kOhms Throttle grip CLOSED resistance across terminals 1 and 2 1 1 kOhms resistance across terminals 1 and 3 1 9 kOhms Throttle grip OPEN resistance across terminals 1 and 2 1 9 kOhms resistance across terminals 1 and 3 1 1 kOhms tolerance on measured values 10 12 Air injector winding resistance 1 3 ohms 13 Coolant temperature sensor NTC sensor resistance 2 7 kOhms at 20 C SR 50 ELECTRICAL S
42. e 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 belt and A frame lift the vehicle rear end Loosen and remove the shock absorber upper screw Loosen and remove the two cable guide screws Loosen and remove the two screws Slide out the rear brake caliper keep it connected to the fluid line ELI 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 hose Fold the lines and tie them Remove the cooling system hose from the head Disconnect the spark plug 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 remove the ground cable SR 50 Disconnect the starter motor positive cable connector and remove the tie Disconnect the two wires Working on the left side loosen and remove the nut Working on the right side remove the pin Remove the engine SR 50 4 2 2 INSTALLING THE ENGINE IE 50 Move the frame small motions until the h
43. ed oil contains substances that are very dangerous for the environment Dispose of used oil in accordance with applicable regulations Fit and tighten the drain screw Pour through the transmission oil filler hole Screw tighten the plug dipstick Start the engine and let it run for a few minutes Stop the engine and let it cool down Check the gear fluid level PERIODIC MAINTENANCE SR 50 2 2 5 GEAR FLUID IE50 CAUTION Use only recommended oil see LUBRICANT CHART CHECK Ride several miles to warm up the engine to operating temperature and then stop the engine Position the vehicle on firm and level ground Position the vehicle on the center stand WARNING Allow several minutes for the engine and exhaust system to cool down Place a graduated receptacle 1 with at least 150 cm capacity 9 15 in under the drain plug 2 Unscrew and remove the filler plug 3 and drain plug 2 Let the oil fully drain off the crankcase Measure the quantity if it is less than 130 cm 7 93 in restore the correct level by topping up see LUBRICANT CHART Tighten the drain plug 2 Refill with the oil recovered the graduated receptacle 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 vehi
44. elease cable and to fuel pump wiring see REMOVING THE FUEL TANK Disconnect the fuel injector connector Disconnect the compressed air inlet line Loosen and remove the two screws Remove the injection unit FUEL SYSTEM SR 50 3 4 4 CARBURETOR 3 4 1 CARBURETOR 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 T 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 FUEL SYSTEM SR 50 3 4 2 REMOVING THE CARBURETOR C 364 e Loosen and remove the two screws Loosen and remove the screw Loosen the carburetor clamp Remove the air box FUEL SYSTEM Disconnect the automatic choke connector Pinch the two heater hoses Remove the two clamps remove the hoses Pinch the fuel hose Remove the tie and disconnect the fuel hose Pinch the hose Remove the tie and disconnect the hose SR 50 FUEL SYSTEM SR 50 Remove the tie and disconnect the vacuum hose Loosen the tie and remove the carburetor from the intake m
45. ent with clean non flammable solvents or solvents with a high volatility point then let it dry thoroughly Apply a filter oil on the entire surface of the filtering element 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 gasoline or solvents since they may cause a fire in the fuel supply system with serious danger for persons in the vicinity and for the vehicle Do not use filters that have already been used Change the air filter with a new one of the same type PERIODIC MAINTENANCE PERIODIC MAINTENANCE 2 2 3 COOLANT CHECKING AND TOPPING UP THE COOLANT LEVEL WARNING Wait for the engine to cool down before checking or topping up the coolant level Stop the engine and wait until it has cooled down CAUTION Place the vehicle on a firm and level surface Remove the front cover see REMOVING THE FRONT COVER sure that the level of the fluid contained in the expansion reservoir is included between the MIN and MAX marks MIN minimum level MAX maximum level If not so Unscrew the filler plug by turning it counterclockwise two turns without removing it Wait few seconds order to release residual pressure Unscrew and remove the plug WARNING Do not put additives or other substances int
46. er Steering head to handlebar fastener 2 Allen 1 20 Steering head to handlebar fastener 1 Self tapping 3 9x14 plastic 0 5 Instrument panel support plate to head battamend fastener 3 Self tapping 3 9x14 plastic 0 5 Front support plate to instrument panel 5 Self tapping 3 9 14 plastic 0 5 _ support plate fastener Handlebar cover to steering head battonrend fastener 4 Self tapping 3 9x14 plastic 0 5 Turn indicators to support plate 4 Self tapping 3 9x14 plastic 0 5 Turn indicator covers fastener 2 Self tapping 3 9x14 plastic 0 5 Headlight fairing to front support plate 4 Allen crowned head screw 4 20 fastener M5x20 addi Controls to handlebar fastener 4 Screw M5 1 Tanks Fuel tank to helmet compartment 3 Allen crowned head 3 20 fastener screw M5x16 with collar TEES Fuel pump support to helmet 5 compartment fastener EE3 1 Screw M5x35 2 20 Oil reservoir and cooling to frame Allen crowned head 1 5 20 fastener screw 5 16 Fuel sensor fastener 4 Nut M4 1 20 Fuel valve to tank fastener 22 1 Tie 16 25 2 PERIODIC MAINTENANCE SR 50 2 1 5 MULTIFUNCTION DIGITAL COMPUTER IE 361 IE 50 Using the MODE joystick Using the MODE joystick on the RH handlebar 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
47. er tripped while starting ECU 17 Engine temperature sensor malfunction ECU 18 Error on ECU throttle sensor connection ECU 22 Atmospheric pressure sensor malfunction ECU 23 INSTRUMENT PANEL ERRORS This menu allows you to view any current errors active or stored memo as detected by the instrument panel The presence of an error is indicated by x To identify the error please refer to the instrument panel error codes table ERROR DESCRIPTION Immobilizer failure Key code read but not acknowledged INSTRUMENT PANEL ERROR CODE Immobilizer failure Key code not read key not available or transponder broken Immobilizer failure Broken antenna open or short circuited Immobilizer failure Inner controller failure Fuel sensor failure 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 WARNING This operation is necessary before connecting to the ECU with AXONE or GAMEBOY in order to avoid disturbances in data transmission across the ECU and diagnosis instrument UPDATE Select this function to cut the instrument panel ECU connection and preset the instrument panel for uploading a new software through AXONE The code of the sof
48. es of fluids to top up the level as this will damage the brake system Do not use brake fluid from containers which have been kept open or in storage for long period of time Any sudden changes in slack 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 come in contact with oil or grease This is particularly important after servicing or inspections Ensure the brake lines are not twisted or worn Avoid accidental entry of water or dust into the circuit Wear latex gloves when servicing the hydraulic circuit DISC BRAKES DANGER The brakes are the vehicle s most important safety component To ensure your personal safety they must be in perfect working order and should be checked before every ride Dirty pads must be replaced Dirty or oily discs must be cleaned with a high quality degreasing product If the vehicle is often used on wet road surfaces or on dusty or rough tracks or in case of use in competition reduce the service intervals by half Check brake pads for wear When the brake pads are worn the fluid level lowers to compensate for the wear The front brake fluid reservoir is on the RH side of the handlebar next to the front brake lever The rear brake fluid reservoir is located under the RH side fairing Do not use the vehicle if the brake system leaks fluid GENERAL INFORMATION SR 50 COOLANT DANGER Coolant is to
49. ess strictly necessary Do not use polishing pastes on matt paints Never use fuel instead of solvent to clean the motorcycle Do not clean rubber or plastic parts or the seat with alcohol gasoline or solvents Use only water and mild soap 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 details see DANGEROUS ELEMENTS BEFORE REMOVING ANY COMPONENTS Clean off all dirt mud and dust and clear any foreign objects from the vehicle before disassembling any components Use the model specific special tools where specified DISASSEMBLING THE COMPONENTS Never use pliers or similar tools to slacken and or tighten nuts and bolts Always use a suitable wrench Mark the positions of all connections hoses wiring etc before disconnecting them Identify each connection using a distinctive symbol or convention Mark each part clearly to avoid confusion when refitting Thoroughly clean and wash any components you have removed using a detergent with low flash point Mated parts should always be refitted together These parts will have seated themselves against one another during running as a result of normal wear and tear and should never be mixed up with other similar parts when refitting Certain components are matched pair parts and should always be
50. f explosive gases Keep the battery well away from any sources of ignition such as flames sparks or any heat sources Make sure the area is well ventilated when servicing or refilling the battery KEEP AWAY FROM CHILDREN Battery fluid is corrosive Avoid spillage Take special care not to spill battery fluid on plastic parts Ensure that the electrolyte fluid you are using is the suitable type for your battery GENERAL PRECAUTIONS AND INFORMATION Follow these instructions closely when repairing disassembling or reassembling the motorcycle or its components 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 the engine and exhaust system to cool down where possible lift the motorcycle using adequate equipment placed on firm and level ground Pay particular attention to any parts of the engine or exhaust system which may still be hot to the touch to avoid burns Never put mechanical parts or other vehicle components in your mouth when you have both hands busy None of the motorcycle components are edible Some components are harmful to the human body or toxic If not expressly indicated otherwise for the reassembly of the units repeat the disassembly operations in reverse order Where a procedure is cross referred to relevant sections in the manual proceed sensibly to avoid disturbing any parts unl
51. improvement of its products as well as of the relevant technical literature All aprilia Dealers and Subsidiaries worldwide are kept updated on major engineering changes and modifications to repair procedures Such changes and modifications are then reflected in the next release of the relevant manual In case of need or doubt regarding repair and inspection procedures contact the aprilia SERVICE DEPARTMENT which will be pleased to help as well as providing you with updates and technical modifications regarding 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 rights of storage using electronic means reproduction and total or partial adaptation whatever the means adopted are reserved in all countries The mention of third parties products is only made for information purposes and constitutes no engagement aprilia s p a is not liable in any way for the performance or use of these products For more details see REFERENCE MANUALS First edition May 2005 Produced and printed by DECA s r l via Vincenzo Giardini 11 48022 Lugo RA Italy Tel 39 0545 216611 Fax 39 0545 216610 E mail deca vftis spx com www vftis com 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
52. in between the frame and the rear wheel to avoid the air box sinking and pushing on the inspection cover Loosen and remove the top screw Loosen and remove the nut and remove the screw Remove the rear shock absorber CYCLE PARTS SR 50 COOLING SYSTEM COOLING SYSTEM COOLING SYSTEM SR 50 TABLE OF CONTENTS Gd COOLING SYSTEM a 3 22 1 LIE LL E M 3 62 EMPTYING THE COOLING SYSTEM nci eco sata scite dites tecti 4 691 EMPTYING THE COOLING rtt tinens kite etta 4 SR 50 6 1 6 1 1 COOLING SYSTEM DIAGRAM Expansion reservoir with plug Radiator Expansion reservoir radiator hose Breather hose Radiator pump hose Head radiator hose To water pump From head COOLING SYSTEM COOLING SYSTEM SR 50 6 2 EMPTYING THE COOLING SYSTEM 6 2 1 EMPTYING THE COOLING SYSTEM CAUTION Before proceeding with emptying the cooling system it is necessary to take a receptacle with a suitable capacity Remove the front cover see REMOVING THE FRONT COVER Unscrew and remove the expansion reservoir plug Remove the lower shield see REMOVING THE LOWER SHIELD Disconnect the generator connector m Place the container under the coolant pump Loosen the clamp and remove the radiator pump hose let the coolant flow in the container CAUTION Once the system is filled bleed air see COOLANT
53. low or if the mixer oil line from the mixer to the reed assembly is removed it is necessary to bleed the system This must be done to avoid damage caused by the engine running with air in the mixer oil system Remove the lower cover see REMOVING THE LOWER COVER Remove the rubber plug Using screwdriver loosen the screw inside the mixer Oil is drained by gravity allow for the oil to flow out without air bubbles Tighten the screw Refit the cover PERIODIC MAINTENANCE SR 50 m X C 2 2 T 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 Remove the plug Fill with see LUBRICANT CHART Refit the plug AIR BLEED CAUTION The vehicle fits a self bleeding electronic pump If the oil in the mixer oil tank is low or if the mixer oil line from the mixer to the reed assembly is removed 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 the throttle twistgrip If necess
54. mp Temperature sensor Pick up sensor Throttle sensor Serial connector diagnosis Pressure sensor or integrated in the control unit ECU Speed sensor Front right turn indicator _ Front parking lights GI only Low beam High beam Front left turn indicator Headlight Diode CABLE COLORS Ar Az B Bi G Gr M N R V Vi Ro Orange Light blue Blue White Yellow Gray Brown Black Red Green Violet Pink ELECTRICAL SYSTEM ELECTRICAL SYSTEM SR 50 7 2 3 WIRING DIAGRAM C 364 SR 50 OCONDARWN gt 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 Rear left turn indicator Tail light Parking light brake light Rear right turn indicator License plate light 6 only Starter relay Starter motor Battery Fuses Regulator Pick up sensor Generator SPARK PLUG Transducer Automatic choke Front right turn indicator Front parking lights 6 only Low beam High beam Front left turn indicator Headlight Serial connector diagnosis ELECTRICAL SYSTEM 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
55. ng a ride do not attempt to continue the trip Avoid sudden braking or steering maneuvers and do not decelerate rapidly Slowly decelerate and move to the edge of the road braking with the engine until you come to a standstill Failure to observe these instructions can result in serious accidents with the risk of serious personal injury or death Never use tube tires on tubeless tire rims or vice versa 1 19 GENERAL INFORMATION SR 50 1 4 RUNNING IN 1 4 1 RUNNING IN Proper engine running in is essential to preserving engine life and performance over time Twisty roads and gradients are ideal to break in engine suspension and brakes effectively Varying speed frequently is also recommended This will vary the amount of stress placed on vehicle components continuously allowing engine parts to cool down when less stressed While it is important to put a certain amount of stress to engine components during the running in period it is equally important to spare the engine at this stage in the vehicle s life WARNING Top acceleration performance is only obtained after covering the first 500 km 312 mi Observe the following instructions e Avoid harsh accelerations and do not flip the throttle open abruptly when the engine is running at low speed both during and after the running in period e Until you have covered the first 100 km 62 mi use the brakes gently and avoid harsh prolonged braking This
56. nner shield to frame fastener 1 screw 5 16 2 Bag hook to inner shield fastener 2 Self tapping 4 2x25 1 2 8 PERIODIC MAINTENANCE SR 50 Description Q ty Type of fastener Tol Note Centre bodywork Passenger footboard platform to frame Allen crowned head 4 2 20 fastener screw M5x16 Under platform to platform fastener 2 Allen crowned head 2 20 screw M5x16 Under platform to platform fastener 6 Self tapping 4 2x16 1 crown cheese headed Platform cover fastener 2 Allen crowned head 2 20 screw M5x16 RH and LH tunnel to platform fastener 2 Allen crowned head 2 20 screw M5x16 RH and LH tunnel to platform fastener 2 Self tapping 4 2x16 1 crown cheese headed Tool compartment to platform fastener 1 Allen crowned head 2 20 screw M5x16 Rear bodywork Tail guard and seat support assy 6 Allen crowned head 2 20 fastener onto fuel tank protector screw M5x16 put License plate holder to fuel tank 4 Allen crowned head 2 20 protector fastener screw M5x16 MIS Allen crowned head Seat support assy to tunnel fastener 4 screw M5x16 2 20 Tail guard to helmet compartment Self tapping 4 2x16 14 0 8 fastener crown cheese headed Allen crowned head Turn indicators to tail guard fastener 2 screw 16 0 5 20 Allen crowned head o Tail light to tail guard fastener 2 screw M4x16 1 20 Grab handle
57. nt 180 kPa 1 8 bar 26 PSI Rear 220 kPa 2 2 bar 32 PSI IGNITION C D TEI T D Spark advance 20 3 before TDC Spark advance mapped to rpm a a throttle opening SPARK PLUG Standard EEE CHAMPION RN1C Standard CHAMPION RG6YCA RG6YC Standard NGK R CPR8E As an alternative NGK R ZMR7AP recommended CR8EKB CR7EKB Spark plug electrode gap EEE 0 6 0 7 mm 0 024 0 028 in Spark plug electrode gap LEJ 0 9 mm 0 035 in ELECTRIC SYSTEM Battery with maintenance 12 V 9 Ah Fuses 7 5A 15A Fuses 10A 15A Fuses 10A Generator with permanent magnet E 12V 70W Generator with permanent magnet DESI 12V 165W Generator with permanent magnet LEJ 12V 140W BULBS Low beam 12V 35 High beam 12V 35W Turn indicators 12V 10 W Rear parking stop light 12V 5 21W Instrument panel lights 12 V LED WARNING LIGHTS High beam 12 V LED Turn indicators 12 V LED Fuel reserve 12 V LED Injection Check 12 V LED SR 50 2 1 2 SCHEDULED MAINTENANCE CHART PERIODIC MAINTENANCE Component After running in 500 km 312 mi Every 4000 km 2500 mi or 12 months Every 8000 km 5000 mi or 24 months Rear shock absorber 1 Battery Electrolyte level 1 SPARK PLUG G E
58. ntenance are covered in the OWNER S MANUAL In this manual any variants are identified with these symbols engine electronic injection Purejet engine electronic injection Ditech EEE carburetor Ea optional catalytic version all versions 11kW derated version 11 KW 80km speed 80km h fp full power version MP national certification SF European certification EURO 1 limits VERSION Greece Qm Malaysia WD United Holland Gm Chile Kingdom Austria Switzerland 4 Croatia Portugal 4D Denmark Australia D Finland Wa Japan CT United States of America Belgium Singapore 4 Brazil Germany Slovenia South Africa France Israel ER New Zealand Spain South Canada Korea 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 A Safety warning When you find this symbol on the vehicle or in the manual be careful to the potential risk of personal injury Disregarding the instructions identified by this symbol may compromise the safety of the user the motorcycle and third parties WARNING A DANGER Indicates a potential hazard which may result in serious injury or even death Indicates a potential hazard which may result minor personal injury damage to the vehicle CAUTION The word CAUTION in
59. o the fluid up the expansion reservoir by adding coolant see LUBRICANT CHART until it almost reaches the MAX level Do not exceed this level otherwise the fluid will flow out while the engine is running Refit the filler plug 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 BLEEDING THE COOLING SYSTEM CAUTION If the coolant in the expansion reservoir is used up or if the circuit is emptied it is necessary to bleed it Proceed as follows Remove the rubber the bleed valve located on the head Fit small tube in the bleed valve and leave the other end in a suitable receptacle Unscrew the bleed valve Fill the expansion reservoir with coolant Bleed the air tighten the valve and continue adding fluid until reaching maximum level SR 50 PERIODIC MAINTENANCE SR 50 Start the vehicle and let it warm up Bleed again and top up PERIODIC MAINTENANCE 2 2 4 GEAR FLUID IE361 C364 CAUTION Use only recommended oil see LUBRICANT CHART Ride several kilometers miles to warm up the engine to operating temperature and then stop the engine Check Position the vehicle on firm and level ground Position the vehicle on the center stand WARNING Allow several minutes for the engine and exhaust system to cool down Unscrew
60. oad rider luggage 105 kg 231 Ib Vehicle max load rider passenger luggage 180 Kg 397 Ib in countries where a passenger is allowed TRANSMISSION SYSTEM Converter Stepless automatic converter Primary V belt Ratios minimum for stepless gearbox 07 3 07 IBESI2 90 maximum for stepless gearbox 1 37 BEI 1 24 10 75 Final gears CARBURETOREEZI Model standard Dell Orto PHVA 17 5 Channel 17 5 mm 0 69 in ELECTRONIC INJECTION FUEL FEEDZET EJ Model standard BING 71 Throttle Q 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 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 Q 190 mm 7 48 in with hydraulic transmission Rear Disc 190 mm 7 48 in with hydraulic transmission WHEEL RIMS Type alloy Front 3 50 x 13 Rear 3 50 x 13 TIRES 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 countries where this is allowed Fro
61. oles match perfectly Working on the right side fit the pin Working on the left side tighten the nut Connect the two wires Connect the starter motor positive cable connector and place a new tie on the wiring 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 SR 50 SR 50 Fit the spark plug Position the cooling system hose onto the head Tighten the clamp Connect the mixer oil hose Place the two intake hoses on the frame ENGINE 4 19 Fit the rear brake caliper 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 Fit the throttle body the fuel tank the battery the lower shield SR 50 SR 50 24 5 4 3 364 4 3 1 364 Remove the brake caliper see REMOVING THE BRAKE CALIPER Loosen and remove the fifteen screws and remove the converter cover Release the mixer pump drive cable Pinch the oil hose delivery Remove the tie and the hose SR 50 Remove the carburetor see REMOVING THE CARBURETOR Remove
62. on Double Countershaft pressure measurement 1 bar 100 kPa Direct Current cubic centimeters 7 carbon oxide Central Processing Unit German industrial standards Deutsche Industrie Norm Double Overhead Camshaft Electronic Control Unit revolutions per minute unburnt hydrocarbons dle Speed Control International Standardization Organization kilograms kilogram per meter 1 kgm 10 Nm kilometers kilometers per hour kiloOhm kiloPascal 1 kPa 0 01 bar clutch side from the German Kupplungseite kiloWatt liters racetrack lap Light Emitting Diode left hand side meters per second maximum millibar 1 mbar 0 1 kPa miles minimum miles per hour flywheel side from the German Magnetoseite MegaOhm Not Available Motor Octane Number Research Octane Number Newton meter 1 Nm 0 1 kgm ohm pick up Bottom Dead Center Top Dead Center Pneumatic Power Clutch right hand side Society of Automotive Engineers Secondary Air System INTRODUCTION INTRODUCTION TEST diagnostic check crowned head Allen screw cheese headed Allen screw T E hexagonal head T P flat head screw TSI Twin Spark Ignition UPSIDE DOWN inverted fork legs V Volt Watt SR 50 SR 50 GENERAL INFORMATION GENERAL INFORMATION 1 GENERAL INFORMATION SR 50 TABLE
63. operated switch Warning horn Left dimmer switch Rear stop switch on left dimmer switch Right dimmer switch Front stop switch on right dimmer switch Rear left turn indicator Tail light Parking light brake light Rear right turn indicator License plate light 6 only Pick up sensor Generator Voltage regulator Injection relay Starter relay noise proof Starter motor Battery Fuses Fuel pump Air injector Fuel injector Pressure sensor or integrated in the control unit Head temperature sensor H T coil Spark plug Throttle sensor Serial connector diagnosis Oil pump ECU Speed sensor Front right turn indicator _ Front parking lights only Low beam High beam Front left turn indicator Headlight Diode ELECTRICAL SYSTEM ELECTRICAL SYSTEM SR 50 7 2 2 WIRING DIAGRAM IE 50 SR 50 OCONDARWN gt 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 Rear left turn indicator Tail light Parking light brake light Rear right turn indicator License plate light 6 2 only Generator Voltage regulator Injection relay Starter relay Starter motor Battery Fuse Spark plug H T coil Fuel pump Air injector Fuel injector Oil pu
64. our hands thoroughly after handling Dispose of it through the nearest waste oil reclamation firm or through the supplier Wear latex gloves during servicing DO NOT DISPOSE OF FLUID IN THE ENVIRONMENT KEEP AWAY FROM CHILDREN BRAKE FLUID WARNING Brake fluid can damage plastic rubber or painted parts When servicing the brake system protect all such parts with a clean cloth Always wear safety glasses when servicing the brake system Brake fluid is highly irritant Avoid contact with the eyes In case of contact with the eyes rinse abundantly with cool clean water and immediately seek medical attention KEEP AWAY FROM CHILDREN GENERAL INFORMATION SR 50 HYDROGEN GAS AND BATTERY ELECTROLYTE DANGER The battery electrolyte is a toxic caustic substance containing sulfuric acid and thus able to cause severe burns in case of contact Wear close fitting gloves and protective clothing when handling this fluid If any battery fluid gets on your skin rinse the affected area with abundant fresh water Take special care to protect the eyes even a very small amount of battery fluid can cause blindness If battery fluid comes in contact with the eyes flush with abundant water for fifteen minutes and contact an eye specialist immediately If battery fluid is swallowed accidentally drink abundant water or milk Seek medical attention immediately and keep drinking milk of magnesia or vegetable oil in the meantime The battery gives of
65. out of the hydraulic circuit after the brakes have been refitted and the braking system has been restored to standard operating conditions as it would be very dangerous for the vehicle and the rider not to do so Loosen the two brake fluid reservoir screws Raise and remove the cover 1 CAUTION It is recommended to keep the fluid even with the edge of the reservoir horizontal in order not to spill fluid when topping up Remove the gasket 2 up fluid if necessary Remove the bleed valve rubber cap e Connect a clear tube section to the bleed valve WARNING Do not soil brake pads or discs with brake fluid Put the free end of the hose into a receptacle Slowly pull the brake lever completely two or three times then keep it pulled Loosen the bleed valve press the lever and check if air bubbles are coming out of the tube together with the fluid WARNING Tighten the bleed valve before releasing the lever in order to prevent air from getting into the brake circuit When air is no longer coming out tighten the bleed valve and release the brake lever CAUTION Repeat the last three steps until the air bubbles have been completely eliminated WARNING After reassembly repeatedly pull the brake lever and check the braking system for correct operation SR 50 SR 50 2 2 2 CLEANING THE AIR FILTER Remove the air filter see REMOVING THE AIR FILTER Wash the filtering elem
66. r i 6 Plantlocation NOALE VE S SCORZ VE 7 Sequential serial number SR 50 GENERAL INFORMATION SR 50 1 6 POSITION OF THE ADHESIVE WARNING LABELS 1 6 1 POSITION OF THE ADHESIVE WARNING LABELS Manufacturer by Aprilia S p A C b t F 187 Ie wi T3OBO 127 ME E t3 50 DT 28 1 pai COLO cy HT p wah 135 19 3 im E 153 355 1 ram St This vahicia conforma apii Fader Motor Vehicle any Scarab eco he tae of on e MOTOR DAIVEN CYCLE VFC E GENERAL INFORMATION SR 50 THE CERTIFICATION LABEL 15 UNDER THE PLASTIC PANEL TO REMOVE THE PAMEL SEE OWNER S MANUAL Falura to mirna can ipad am accidant and serious injurias or death USE UNLEADED FUEL MINIMUM OCTANE RATING A 2 METHOD 80 owner s manual for the connect running im and maintenance of the vehicle aprilia BATTERY SERVICE WARNING Maintain electrolyte level between the tie marks Uss andy distilled water Always keep the battery charged Hovor disconnect the battery or regulator with the engine running This will destroy the emilre electrical system GENERAL INFORMATION SR 50 Canin aulfunle acid whieh caes caca Injuries Avoid phyaiclan masiny Eyes with wader for 15 od get prog medical KEEP OUT OF REACH OF
67. r caliper fastener 22 2 screw M8x35 27 10 Rear brake fluid line tie fastener 1 Flanged head screw 10 20 M6x35 Handlebar Safety screw fastener for fork onto 1 Flanged hex head screw 25 20 handlebar 8 40 Allen cheese headed 20 Handlebar clamp to fork fastener 1 screw M10x55 50 Allen cheese headed 20 Right and left mirror securing screw 2 screw M8x35 25 i 0 Brake master cylinders to handlebar 4 Screw M6x25 10 20 fastener Front bodywork Self tapping 3 9x14 _ Door to wheelhouse fastener 2 plastic 0 8 Flanged hex head screw Front mudguard to insert rear fastener 2 M5x40 1 Mudguard front fastener 2 crowned 2 20 screw 5 16 Fastener for wheelhouse onto grid 40 Self tapping 4 2x16 1 _ frame side panels and under platform crown cheese headed Self tapping 3 9x14 _ Scoops to side panels fastener 4 plastic 0 8 Allen crowned head Headlight to side panels fastener 4 screw 4 16 1 20 Allen crowned head Radiator conveyor fastener 4 screw 5 16 with collar 5 20 Grid frame to inner grid fastener Self tapping 2 9x12 0 3 Complete frame to side panels 6 Self tapping 3 9x14 0 8 _ fastener plastic Self tapping 4 2x16 _ Front cover to inner shield fastener 2 drown dhedsedeaded 1 Inner shield to side panels and 40 Self tapping 4 2x16 1 _ platform fastener crown cheese headed Side panels to inner shield upper 2 Self tapping 3 9x14 0 8 _ fastener plastic Allen crowned head I
68. ral screw SR 50 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 CYCLE PARTS SR 50 5 1 11 REMOVING THE FRONT WHEELHOUSE Remove the headlight see REMOVING THE HEADLIGHT Remove the front wheel see REMOVING THE FRONT WHEEL Remove the front mudguard see REMOVING THE FRONT MUDGUARD Loosen and remove the two front screws Release the tie and the two cooling system hoses Loosen and remove the two inner screws e Release the two wheelhouse shells and slide them out of the fork SR 50 5 1 12 THE INSTRUMENT PANEL e Loosen and remove the four front screws Remove the headlight fairing Loosen and remove the three top screws Loosen and remove the two lower screws Release the handlebar fairing move it down and keep it connected to the turn indicator wirings Disconnect the instrument panel connector WARNING During reassembly ensure to perfectly align the connector with the instrument panel to avoid damaging the instrument panel pins CYCLE PARTS CYCLE PARTS Loosen and remove the three screws of the instrument panel subframe Remove the instrument panel SR 50 SR 50 5 2 EXHAUST SYSTEM 5 2 1 REMOVING THE EXHAUST SYSTEM IE361 C364 Remove the lower shield see REMOVING THE LO
69. replaced as a set Keep away from heat sources GENERAL INFORMATION SR 50 REASSEMBLING THE COMPONENTS DANGER Never reuse a circlip or snap ring These parts must always be replaced once they have been removed When fitting a new circlip or snap ring open the ends just enough to allow fitting to the shaft Make a rule to check that a newly fitted circlip or snap ring is fully housed in its groove Never use compressed air to clean bearings CAUTION All bearings must run freely with no hardness 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 the specified torque has been achieved Replace any self locking nuts gaskets seals circlips or snap rings O rings split pins bolts and screws which have a damaged thread Lubricate bearings abundantly before assembly Make 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 grea
70. reservoir Loosen and remove the two screws PERIODIC MAINTENANCE PERIODIC MAINTENANCE WARNING Avoid prolonged 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 the level Raise and remove the cover 1 Remove the gasket 2 CAUTION order not to spill the brake fluid while topping up do not shake the vehicle up the tank 3 with brake fluid to the correct level WARNING Never top up to the maximum level just top up until the level is above the MIN mark It is advisable to top up until reaching the MAX level only with new pads The 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 refit components follow the disassembly procedure in reverse order CHANGING THE BRAKE FLUID Remove the bleed valve rubber cap Insert one end of a transparent plastic tubing inside the caliper bleed valve and the other end in a receptacle for collection Loosen the bleed valve by about turn CAUTION While carrying out this operation ensure that some fluid is always present inside the reservoir If this is not the case once the operation is over the air must be bled out Check that the fluid is flowing off the tank and before emptying tighten the
71. screw Loosen and remove the mudguard front left screw Remove the front 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 Remove the rear mudguard CYCLE PARTS SR 50 5 1 8 REMOVING THE TOOL KIT COMPARTMENT Lift and remove the tool kit compartment cover Loosen and remove the screw Remove the tool kit compartment CYCLE PARTS SR 50 5 1 9 REMOVING THE INNER SHIELD Remove the front cover see REMOVING THE FRONT COVER Loosen and remove the two screws Loosen and remove the ten screws Loosen and remove the two screws of the bag hook Remove the bag hook Loosen and remove the screw below the bag hook CYCLE PARTS SR 50 Remove the rubber element 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 CYCLE PARTS 5 1 10 REMOVING THE HEADLIGHT Remove the front cover see REMOVING THE FRONT COVER Loosen and remove the two screws Loosen and remove the eight screws Working on either side loosen and remove the three inner screws Loosen and remove the cent
72. se along the edges of oil seals Fit oil seals and bearings with the marking or serial number facing outwards in view ELECTRICAL CONNECTORS Disconnect electrical connectors as follows failure to follow these instructions can seriously damage the connectors and the wiring Press the special safety hooks where fitted WARNING Never separate two connectors by pulling on the wiring Grasp both connectors and pull them in two opposite directions until they become separated Remove dirt rust moisture etc from inside the connectors with compressed air Ensure that the wires are securely crimped to the terminals inside each connector CAUTION A connector will fit properly only in the matching connector and when inserted in the correct fitting position Reconnect the two connectors Make sure they are correctly coupled if fitted with hooks it should click audibly into place TIGHTENING TORQUES DANGER Do not forget that the tightening torques of all wheel brake wheel shaft and other suspension parts are essential to ensuring safe operation of the motorcycle and must be set to the indicated values Ensure that these values are always within the specified limits Regularly check the tightening torques on all fastenings and always use a torque wrench when fitting them Failure to observe these instructions can result in parts loosening or coming away thus jamming a wheel or creating other problems which would affect the handling
73. ses for a quick light off of the catalyst The secondary air system is especially useful when the engine is idling and during warm up since the catalyst alone is not capable of triggering post combustion under these operating conditions DESCRIPTION OF THE SYSTEM The secondary air system operates on pressure fluctuation in the exhaust system During depression stages the exhaust takes in oxygen rich air from the secondary air system so unburnt gasses in the exhaust stream can complete the combustion During overpressure stages the secondary air reed valve cuts air supply to prevent backflow On 4 stroke engines the reed valve is equipped with a cut off device that shuts down additional air during cut off stages as exceedingly lean exhaust gasses would lead to exhaust blowing resulting in exhaust valve and catalytic converter damage DETAILS OF SAS The system consists of a rubber hose that takes filtered air in through a scoop on the casing Secondary air flow is controlled by a reed check valve on the vehicle right hand side on the flywheel cover The secondary air tube is connected to flanged metal fitting attached directly to the head exhaust duct ENGINE 4 31 REMOVING AND CLEANING THE AIR FILTER Loosen the two screws and remove the aluminum cover of the system Remove the plastic cover and the filter Remove the single acting valve housing check the valve condition
74. this manual identifies important information or instructions GENERAL INFORMATION SR 50 1 2 GENERAL RULES 1 2 1 BASIC SAFETY RULES CARBON MONOXIDE When an operation must be performed with the engine running position the motorcycle outdoors in a well ventilated area Never run the engine in an enclosed place Use an exhaust emission extraction system when working indoors DANGER Exhaust gases contain carbon monoxide a poisonous gas which if inhaled may cause loss of consciousness or even death FUEL DANGER The fuel used to operate engines is highly flammable and becomes explosive under particular conditions Refueling and maintenance operations should be carried out in a well ventilated area with the engine off Do not smoke when refueling or in the proximity of sources of fuel vapors Avoid contact with bare flames sources of sparks and any other source which may ignite fuel or lead to explosion DO NOT DISPOSE OF FUEL IN THE ENVIRONMENT KEEP AWAY FROM CHILDREN HOT COMPONENT PARTS The engine and exhaust component parts become hot when the engine is running and will stay hot for some time after the engine has been stopped Wear insulating gloves before handling these components or allow for the engine and the exhaust system to cool down before proceeding USED GEARBOX AND FORK FLUIDS DANGER Wear latex gloves when servicing Prolonged or repeated contact with gear fluid may cause severe skin damage Wash y
75. tware currently loaded in the instrument panel is in brackets PERIODIC MAINTENANCE ELI PERIODIC MAINTENANCE CHANGE KEYS The instrument panel manages the immobilizer function through encoded keys In case the keys are lost or the kill switch is changed it is possible to encode up to 4 keys using this procedure At the beginning of the procedure you will be prompted to enter the USER CODE WARNING The user code stored on a new vehicle is 00000 The instrument panel prompts you to insert the first key AN WARNING The first key is the one already inserted Wait for the key to be stored and the second key to be requested Insert the second key within twenty seconds from the request Proceed with the other keys or let the countdown reach zero to end the operation SR 50 SR 50 RESTORE CODE If the user forgets 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 KM MILES use this function to select the unit of measurement for the Tachometer Odometer ESC Select this item to quit the diagnosis environment LANGUAGE FUNCTION sub menu choose the desired language from this menu Briefly press the MODE button to enter use the UP and DOWN keys to choose the desired language among the available ones and set it by pressing the MODE key for a certain time PERIODIC MAINTENANCE ELI
76. uel tank 88 ohms with half full fuel tank 100 ohms with empty fuel tank 8 Fuses 10A fuse 1 From ignition switch to Lights Low High beam relay 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 12V 35W high beam 12V 35W ELECTRICAL SYSTEM 11 Throttle body FUEL INJECTOR winding resistance 1 7 ohms THROTTLE POSITION SENSOR TPS resistance across terminals 1 and 4 1 1 kOhms Throttle grip CLOSED resistance across terminals 1 and 2 1 1 kOhms resistance across terminals 1 and 3 1 9 kOhms Throttle grip OPEN resistance across terminals 1 and 2 1 9 kOhms resistance across terminals 1 and 3 1 1 kOhms tolerance on measured values 10 12 Air injector winding resistance 1 3 ohms 13 Coolant temperature sensor NTC sensor resistance 2 7 kOhms at 20 C SR 50 ELECTRICAL SYSTEM 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 win
77. will help the brake pads bed in properly against the brake disc e During the first 300 km 187 mi do not keep the throttle twistgrip open for more than half of its stroke for long periods of time e From 300 to 500 km 187 312 mi do not keep the throttle twistgrip open for more than three fourths of its stroke for long periods of time A WARNING After covering the first 1000 km 625 mi perform the checks listed in the After running in column see REGULAR SERVICE INTERVALS CHART to avoid personal injury to yourself or third persons or vehicle damage GENERAL INFORMATION 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 A is stamped on the frame central tube To read it it is necessary to remove the indicated cover 1 CAUTION The cover 1 can be fitted only in one position The tabs 2 are on the sides ENGINE NUMBER The engine number is stamped near the lower support of the rear shock absorber DIGIT MEANING month year 1 Manufacturer s identification alphanumeric code aa 2 Vehicle type Meer 3 of cycle line Engine type and Engine Net Brake eese Mg ie Horse Power h O PEISE De e 4 Check digit number ID c i re aiaa 5 Model yea
78. wn the Mode button 2 again for at least three seconds to shift to the minute setting The indicated value will increase by one unit every time the Mode button 2 is pressed Hold down the Mode button 2 for at least three seconds to go back to the hour setting If no key has been touched for three seconds the display will automatically quit the clock setting function Y SR 50 SR 50 2 2 SCHEDULED MAINTENANCE 2 2 1 BRAKE 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 Prevent water or dust from accidentally getting into the circuit CAUTION The following procedure refers to both brake systems Check CAUTION Place the vehicle on a firm and level surface Position the vehicle the center 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 The brake fluid level decreases as the brake pads wear down Check brake pads for wear If the pads and or the disc do not need replacing top up 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 Place a cloth under the brake fluid
79. xic when swallowed and is an irritant Contact with the eyes or skin can cause irritation In the event of contact with the skin or eyes rinse repeatedly with abundant water and seek medical attention If swallowed induce vomiting rinse mouth and throat with abundant water and seek medical attention immediately DO NOT DISPOSE OF IN THE ENVIRONMENT KEEP AWAY FROM CHILDREN DANGER Avoid spilling coolant onto hot engine parts as it may ignite and produce invisible flames Wear latex gloves when servicing Do not ride the vehicle when coolant is below the minimum level Coolant mixture is a 5096 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 mineral salts depositing in the radiator which helps preserve the efficiency of the cooling system When the temperature drops below 0 C 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 Freezing point C Coolant 96 of volume 20 4 35 3
80. y of the caliper on the disc While changing pads protect the rim with tape CYCLE PARTS 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 are not in place or the caliper piston might come off its housing thus causing brake fluid leakage Always change both pads and ensure they are correctly in place inside the caliper Fit two new brake pads 4 Correctly seat the spring 3 Fit the 2 Fit the snap ring 1 For the front brake caliper only Refit the brake caliper cover Check the brake fluid level see BRAKING SYSTEM SR 50 YCL SR 50 CYCLE PARTS 5 6 STEERING 5 6 1 STEERING DIAGRAM Key Dust seal Lock nut Adjuster nut Upper bearing Lower bearing Steering CYCLE PARTS SR 50 5 7 FRONT FORK 5 7 1 FRONT FORK DIAGRAM Key 1 Rubber cap 2 Snap ring 3 Fork clamp bolts 4 Snap ring 5 Sealing cap 6 O ring T 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 CYCLE PARTS SR 50 5 7 2 REMOVING THE FORK LEG Remove the headlight see REMOVING THE HEADLIGHT Remove the front wheel

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