APRILIA SR 50 - BROCHURE 2009 Gebrauchsanweisung

www.serviceaprilia.com

workshopmanual

SR 50

1228 4

00/2004-10

8140816 UK

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INTRODUCTION

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INTRODUCTION 0

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INTRODUCTION

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SUMMARY

0.1. FOREWORD..................................................................................................................................................... 3

0.1.1. FOREWORD ............................................................................................................................................. 3

0.1.2. REFERENCE MANUALS .......................................................................................................................... 4

0.1.3. ABBREVIATIONS/SYMBOLS/CONVENTIONS ........................................................................................ 5

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INTRODUCTION

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0.1. FOREWORD

0.1.1. FOREWORD

- This manual provides the information required for normal servicing.

- This publication is intended for use by aprilia Dealers and their qualified mechanics; many concepts have been

omitted on purpose as their inclusion would be superfluous. Since complete mechanical explanations have not been

included in this manual, the reader must be familiar with basic notions of mechanics, as well as with basic repair

procedures. Without such familiarity, repairs and checks could be ineffective and even hazardous. Since not all

vehicle inspection and repair procedures are described in details, pay utmost attention to avoid damages to

components or people. aprilia s.p.a. undertakes to constantly improve the design of its products and their literature

to ensure that the customer is satisfied of the product. The main technical modifications and changes in repair

procedures are communicated to all aprilia dealers and agencies worldwide. These changes will be applied to the

next issues of this manual. Should you need assistance or clarifications about the inspection and repair procedures,

please contact the aprilia SERVICE DEPT., they will be glad to give you any information on the matter, or supply

you with any detail on updates and technical changes applied to the vehicle.

aprilia s.p.a. reserves the right to make changes to its products at any time, barring any such changes as may alter the

essential features of a product as specified in the relevant manual.

All rights of electronic storage, reproduction and total or partial adaptation with any means reserved for all Countries.

Third parties' products are only mentioned for information purposes, and constitute no engagement.

aprilia s.p.a. is not liable in any way for the performance or use of these products.

For further details, see (REFERENCE MANUALS).

First edition: October 2004

Produced and printed by:

DECA S.r.l.

via Risorgimento, 23/1 - 48022 Lugo (RA) - Italy

Tel. +39 - 0545 35235

Fax +39 - 0545 32844

E-mail: [email protected]

www.decaweb.it

On behalf of:

aprilia s.p.a.

via G. Galilei, 1 - 30033 Noale (VE) - Italy

Tel. +39 – (0)41 58 29 111

Fax +39 – (0)41 58 29 190

www.aprilia.com

www.serviceaprilia.com

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INTRODUCTION

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0.1.2. REFERENCE MANUALS

SPARE PARTS CATALOGUES

Version

aprilia part# (description)

5564_00

Version

aprilia part# (description)

5574_00

OWNER'S MANUALS

aprilia part#

8202397

8202441

8202442

8202439

ENGINE WORKSHOP MANUAL

Engines

aprilia part#

8140818

8140821

8140819

8140820

8140822

8CM0067

ENGINE WORKSHOP MANUAL

Engines

aprilia part#

8140645

8140646

8140647

8140648

8140649

8CM006

CHASSIS WORKSHOP MANUAL

aprilia part#

8140812

8140815

8140813

8140814

8140816

8140817

8CM0064

8CM0065

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INTRODUCTION

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0.1.3. ABBREVIATIONS/SYMBOLS/CONVENTIONS

# = number

< = less than

> = greater than

≤= less than or equal to

≥= more than or equal to

~ = approximately

∞= infinity

°C = degrees Celsius (centigrade)

°F = degrees Fahrenheit

± = plus or minus

a.c = alternating current

A = Ampere

Ah = Ampere per hour

API = American Petroleum Institute

AT = high voltage

AV/DC = Anti-Vibration Double Countershaft

bar = pressure measurement (1 bar = 100 kPa)

d.c. = direct current

cc = cubic centimetres

CO = carbon monoxide

CPU = Central Processing Unit

DIN = German industrial standards (Deutsche Industrie Norm)

DOHC = Double Overhead Camshaft

ECU = Electronic Control Unit

rpm = revolutions per minute

HC = unburnt hydrocarbons

ISC = Idle Speed Control

ISO = International Standardisation Organisation

kg = kilograms

kgm = kilogram metre (1 kgm = 10 Nm)

km = kilometres

km/h = kilometres per hour

kΩ= kilo Ohm

kPa = kiloPascal (1 kPa = 0.01 bar)

KS = clutch side (from the German "Kupplungseite")

kW = kilowatt

l = litres

LAP = racetrack lap

LED = Light Emitting Diode

LEFT SIDE = left side

m/s = metres per second

max = maximum

mbar = millibar (1 mbar = 0.1 kPa)

mi = miles

MIN = minimum

MPH = miles per hour

MS = flywheel side (from the German "Magnetoseite")

MΩ= MegaOhm

N.A. = Not Available

N.O.M.M. = Motor Octane Number

N.O.R.M. = Research Octane Number

Nm = Newton metre (1 Nm = 0.1 kgm)

Ω= ohm

PICK-UP = pick-up

BDC = Bottom Dead Centre

TDC = Top Dead Centre

PPC = Pneumatic Power Clutch

RIGHT SIDE = right side

SAE = Society of Automotive Engineers

SAS = Secondary Air System

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INTRODUCTION

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TEST = diagnostic check

T.B.E.I. = crown-head Allen screw

T.C.E.I. = cheese-head Allen screw

T.E. = hexagonal head

T.P. = flat head screw

TSI = Twin Spark Ignition

UPSIDE-DOWN = inverted fork

V = volt

W = watt

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GENERAL INFORMATION

1 - 1

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GENERAL INFORMATION 1

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GENERAL INFORMATION

1 - 2

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SUMMARY

1.1. STRUCTURE OF THE MANUAL...................................................................................................................... 3

1.1.1. CONVENTIONS USED IN THE MANUAL ................................................................................................. 3

1.1.2. SAFETY WARNINGS ................................................................................................................................ 4

1.2. GENERAL RULES............................................................................................................................................ 5

1.2.1. BASIC SAFETY RULES ............................................................................................................................ 5

1.3. DANGEROUS ELEMENTS............................................................................................................................... 8

1.3.1. WARNINGS ............................................................................................................................................... 8

1.4. RUNNING-IN .................................................................................................................................................. 11

1.4.1. RUNNING-IN ........................................................................................................................................... 11

1.5. VEHICLE IDENTIFICATION ........................................................................................................................... 12

1.5.1. POSITION OF THE SERIAL NUMBERS ................................................................................................. 12

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GENERAL INFORMATION

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1.1. STRUCTURE OF THE MANUAL

1.1.1. CONVENTIONS USED IN THE MANUAL

• This manual is divided in sections and subsections, each covering a set of the most significant components. Refer to

the index of sections when consulting the manual.

• Unless expressly specified otherwise, assemblies are reassembled by reversing the dismantling procedure.

• The terms "right" and "left" are referred to the rider seated on the vehicle in the normal riding position.

• Motorcycle operation and basic maintenance 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

carburettor

optional

catalytic version

- all versions

11kw derated version 11 kw

80km speed 80km/h

f.p full-power version

MP national certification

SF European certification (EURO 1 limits)

VERSION:

Italy Greece Malaysia

United

Kingdom Holland Chile

Austria Switzerland Croatia

Portugal Denmark Australia

Finland Japan United

States of

America

Belgium Singapore Brazil

Germany Slovenia South Africa

France Israel New

Zealand

Spain South

Korea Canada

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