Welcome to the comprehensive service manual for the SMT RCR50, covering model years 2005 through 2009. This Supermoto/Enduro Moped is celebrated for its agile handling, sporty styling, and lightweight construction, making it an excellent choice for urban commuting and light off-road adventures. As an entry-level performance 50cc light motorcycle, the SMT RCR50 embodies a heritage of Italian engineering and a pedigree in performance-oriented vehicles. Its design prioritizes rider engagement and capability, positioning it as a competitive option within its class. This factory service repair workshop manual provides comprehensive coverage for all aspects of the SMT RCR50. Inside, you will find detailed information on engine, electrical systems, cooling, braking, suspension, and chassis maintenance and repair. The manual includes essential procedures such as diagnostic steps, engine overhaul, carburetor service, pre-delivery inspections, and troubleshooting guides for common issues. It is designed to empower owners and technicians alike, offering the factory-level diagnostic and repair data necessary for optimal upkeep, performance, and longevity of your SMT RCR50. 🏷️ Basic Information Identification Make: Gilera Model: SMT RCR50 Years Covered: 2005, 2006, 2007, 2008, 2009 Vehicle Type: Supermoto/Enduro Moped Codes Manual Product Code: GIL-SMT-RCR50-2005-2009-SM-PDF 👋 Introduction Market Position Market Segment: Entry-level performance 50cc light motorcycle (moped/supermoto) Competitive Analysis Competitors: Derbi Senda, Aprilia SX50, Rieju MRT50, Yamaha DT50 Key Features Vehicle Focus: Agile handling, sporty styling, lightweight construction, suitable for urban commuting and light off-road use Manual Value Proposition Manual Purpose: Empower owners and technicians with factory-level diagnostic and repair data for optimal vehicle upkeep and performance. 📋 Manual Details Coverage Areas Primary Coverage: Comprehensive Service, Repair, and Maintenance Page Count Page Count: 118 Manual Type Manual Type: Factory Service Repair Workshop Manual Language Language: English Format File Format: PDF Download 📖 Manual Coverage Systems Covered Systems: Engine, Electrical System, Power Supply, Cooling System, Braking System, Suspensions, Chassis, Bodywork, Maintenance, Troubleshooting, Special Tools Electrical System Details: Detailed wiring diagrams, component identification, troubleshooting for lighting, ignition, starting system, and indicators. Chassis Details: Frame, swingarm, wheel bearings, steering head bearings, mounting points. Suspension Details: Front telescopic forks (specifications, seal replacement, oil levels/types), rear monoshock (adjustment, overhaul). Braking System Details: Hydraulic system diagnostics, caliper overhaul, master cylinder service, pad replacement, bleeding procedures. Procedures Included Procedures: Diagnostic procedures, repair procedures, maintenance schedules, pre-delivery inspections, troubleshooting guides, wiring diagram interpretation Engine Overhaul: Complete engine disassembly, inspection, component replacement (piston, rings, bearings, seals), reassembly, and tuning. Carburetor Service: Disassembly, cleaning, reassembly, jetting adjustments, float height setting, idle speed adjustment. Pre Delivery: Comprehensive pre-delivery inspection checklist and procedures for ensuring the vehicle is ready for customer use. Technical Depth Depth: Detailed diagnostic information, component-level repair instructions, torque specifications, clearances, electrical system schematics Diagnostic Tools: Highlights special tools required for specific repairs and diagnostics. Torque Specifications: Detailed torque values for critical fasteners throughout the motorcycle. 📊 Manual Specifications File Format Compatibility: All Versions of Windows & Mac Reader Requirement: Adobe PDF Reader Print Quality Print Quality: High-resolution, suitable for printing detailed diagrams and text Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 2-stroke, single-cylinder Engine Displacement: 49.7 cc Bore X Stroke: 39.5 mm x 40 mm (typical for AM6 based engines) Performance Horsepower: Approximately 8-10 HP (stock, depending on specific market regulations) Torque: Estimated 5-7 Nm (stock) Fuel System Fuel Delivery: Carburetor (e.g., Dell'Orto PHVA 17.5) Fuel Type: Unleaded Gasoline (Octane rating specified in manual) Ignition System Ignition Type: Electronic Ignition (CDI) Cooling System Cooling Method: Liquid-cooled Engine From Vehicle Engine Removal Procedure: Detailed step-by-step instructions for engine removal and reinstallation 🔧 Transmission Standard Transmission Type: 6-speed Manual Features Clutch Type: Wet multi-plate clutch Fluid Specifications Transmission Oil Type: Specific gear oil/transmission fluid as per Gilera's recommendation (e.g., SAE 80W/90) 📐 Dimensions Exterior Dimensions Overall: Refer to manual for precise dimensions (typical for this class: Length ~2000mm, Width ~750mm, Height ~1100mm) Weights Dry Weight: Approximately 90-100 kg Max Load Capacity: Refer to manual (typically around 100-120 kg including rider and cargo) 🛡️ Safety Features Ratings Safety Ratings: N/A (Moped category typically not subject to stringent crash ratings like cars) Active Features Braking System Front: Hydraulic Disc Brake (e.g., 260mm diameter, 2-piston caliper) Braking System Rear: Hydraulic Disc Brake (e.g., 220mm diameter, 1-piston caliper) Passive Features Lighting: Headlight, Taillight, Brake Light, Turn Signals (covered in electrical section) 💡 Technology Features Infotainment Instrumentation: Analog/Digital Speedometer, Tachometer, Odometer, Fuel Gauge (if equipped), Neutral Indicator, Turn Signal Indicators. Driver Assistance Driver Assistance Features: N/A (basic motorcycle technology) Connectivity Connectivity Features: N/A 🔧 Maintenance Service Intervals Oil Change Interval: Refer to manual for specific mileage/time interval (typical for 2-stroke: regular checks) Spark Plug Replacement: Refer to manual (typical: 3,000-6,000 km or as needed) Air Filter Cleaning: Refer to manual (frequent checks, cleaning/replacement as per conditions) Fluid Specifications Coolant Type: Ethylene glycol based antifreeze coolant (specific mixture ratio...