Aprilia SR50 SR 50 2005 Factory Service Repair Manual
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🏷️ Basic Information Identification Make: Aprilia Model: SR50 Factory Model Year: 2005 Product Type: Factory Service Repair Manual Product Format: Download PDF 👋 Introduction Market Position Segment: High-performance 50cc scooter segment, known for its sporty design and advanced features. Competitive Analysis Competitors: Competes with other premium 50cc scooters from brands like Yamaha (Aerox), Piaggio (Zip SP), and Peugeot (Speedfight). Key Features Vehicle Performance Focus: Emphasis on sporty handling and acceleration, often featuring upgraded components for its class. Key Features Manual Value Proposition: Provides factory-level repair and maintenance information, empowering owners and technicians to perform accurate and efficient servicing. 📋 Manual Details Coverage Areas Covered Systems: Engine, Fuel System, Ignition System, Cooling System, Exhaust System, Transmission (CVT), Chassis, Suspension, Brakes, Electrical System, Lighting, Bodywork, Troubleshooting, Maintenance Schedules, Specifications Page Count Estimated Pages: Hundreds of pages Manual Type Type: Complete Official Factory Service Repair Manual Language Language: English Format Format Details: Searchable PDF, printable 📖 Manual Coverage Systems Covered Engine Mechanical: Engine disassembly, assembly, cylinder head, piston, crankshaft, connecting rod, valve timing, lubrication, cooling system operation and repair. Fuel System: Carburetor specifications, adjustments, cleaning, fuel pump, fuel lines, fuel tank service. Ignition System: Ignition coil, spark plug specifications, timing, CDI unit, troubleshooting. Transmission Drivetrain: Continuously Variable Transmission (CVT) operation, variator, clutch, belt replacement, gear oil specifications and change intervals. Chassis Suspension: Front fork service, rear shock absorber replacement, steering system overhaul, frame inspection. Brakes: Front and rear brake caliper service, hydraulic lines, brake fluid specifications and bleeding procedures, master cylinder overhaul, brake pad replacement. Electrical Lighting: Wiring diagrams, battery specifications, charging system, starter motor, lighting circuits, fuses, indicators, horn. Procedures Included Maintenance: Regular scheduled maintenance, fluid level checks, filter replacements, lubrication points, brake adjustments. Troubleshooting: Diagnostic procedures for common issues, symptom-based problem solving, electrical and mechanical troubleshooting trees. Repair: Step-by-step instructions for component removal, repair, and reinstallation across all major vehicle systems. Diagnostics: Detailed diagnostic charts for identifying and resolving performance issues, electrical faults, and mechanical problems. Technical Depth Depth: Comprehensive, from basic adjustments to complete engine and transmission rebuilds. Includes detailed diagrams and specifications for factory-level repairs. 📊 Manual Specifications File Format File Type: PDF Print Quality Printability: High resolution, suitable for printing individual sections or the entire manual. Binding Type Binding: Not applicable (downloadable PDF) Paper Type Paper: Not applicable (digital format) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 2-stroke, single-cylinder Displacement: 49cc (approx.) Bore X Stroke: Refer to manual for exact specifications (e.g., 40mm x 39.2mm for some variants) Power Output: Refer to manual for exact specifications (typically around 5-7 hp depending on variant and restrictions) Torque: Refer to manual for exact specifications Fuel System Fuel Delivery: Carburetor (e.g., Dell'Orto PHVA 17.5) Fuel Type: Unleaded gasoline (minimum 95 RON recommended) Oil Mixing: Automatic oil injection system (separate oil reservoir) Cooling System Cooling Method: Liquid-cooled Coolant Type: Ethylene glycol-based coolant (50% mixture with distilled water) Ignition System Ignition Type: Electronic ignition (CDI) Spark Plug Type: Refer to manual for specific NGK or equivalent part number (e.g., NGK BR9ES) 🔧 Transmission Standard Transmission Type: Automatic Continuously Variable Transmission (CVT) Drive System: Belt drive to rear wheel Features Clutch Type: Automatic centrifugal clutch Gear Ratios: Variable (CVT), gear reduction ratios provided in manual Transmission Fluid: Not applicable for CVT, but drive unit requires specific gear oil (refer to manual for type and capacity) 📐 Dimensions Exterior Length: Refer to manual for exact dimensions Width: Refer to manual for exact dimensions Height: Refer to manual for exact dimensions Weights Dry Weight: Refer to manual for exact weight (typically around 90-100 kg) Fuel Tank Capacity: Refer to manual for exact capacity (typically around 7-8 liters) Wheels Tires Front Tire Size: Refer to manual for exact size (e.g., 130/60-13) Rear Tire Size: Refer to manual for exact size (e.g., 140/60-13) Wheel Bolt Pattern: Not applicable (scooter specific hub mounting) 🛡️ Safety Features Ratings Safety Standards: Complies with relevant European safety standards for mopeds and scooters. Active Features Braking System: Hydraulic disc brakes front and rear. Lighting: Halogen headlight, LED taillight, turn signals. Passive Features Chassis Construction: Steel frame providing a stable and robust platform. Bodywork: Aerodynamic fairing for rider protection and stability. 💡 Technology Features Infotainment Instrument Cluster: Digital/analog instrument cluster with speedometer, tachometer, fuel gauge, coolant temperature warning, and indicator lights. Driver Assistance Braking Assist: ABS was not standard on most 2005 SR50 models; manual covers conventional braking system. Connectivity Connectivity Features: No advanced connectivity features typical of modern vehicles; focus is on mechanical and electrical systems. 🔧 Maintenance Service Intervals Oil Change Engine: Refer to manual for specific interval based on mileage or time (typically every 3,000-5,000 km) Spark Plug Replacement: Refer to manual for interval (e.g., every 5,000-7,000 km) Air Filter Cleaning Replacement: Refer to manual for interval (e.g., every 3,000-5,000 km or as needed based on conditions) Brake Fluid Change:...
Ignition coil, spark plug specifications, timing, CDI unit, troubleshooting.
Transmission Drivetrain:
Continuously Variable Transmission (CVT) operation, variator, clutch, belt replacement, gear oil specifications and change intervals.
Chassis Suspension:
Front fork service, rear shock absorber replacement, steering system overhaul, frame inspection.
Brakes:
Front and rear brake caliper service, hydraulic lines, brake fluid specifications and bleeding procedures, master cylinder overhaul, brake pad replacement.
Diagnostic procedures for common issues, symptom-based problem solving, electrical and mechanical troubleshooting trees.
Repair:
Step-by-step instructions for component removal, repair, and reinstallation across all major vehicle systems.
Diagnostics:
Detailed diagnostic charts for identifying and resolving performance issues, electrical faults, and mechanical problems.
Technical Depth
Depth:
Comprehensive, from basic adjustments to complete engine and transmission rebuilds. Includes detailed diagrams and specifications for factory-level repairs.
📊 Manual Specifications
File Format
File Type:
PDF
Print Quality
Printability:
High resolution, suitable for printing individual sections or the entire manual.
Binding Type
Binding:
Not applicable (downloadable PDF)
Paper Type
Paper:
Not applicable (digital format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, 2-stroke, single-cylinder
Displacement:
49cc (approx.)
Bore X Stroke:
Refer to manual for exact specifications (e.g., 40mm x 39.2mm for some variants)
Power Output:
Refer to manual for exact specifications (typically around 5-7 hp depending on variant and restrictions)
Torque:
Refer to manual for exact specifications
Fuel System
Fuel Delivery:
Carburetor (e.g., Dell'Orto PHVA 17.5)
Fuel Type:
Unleaded gasoline (minimum 95 RON recommended)
Oil Mixing:
Automatic oil injection system (separate oil reservoir)
Cooling System
Cooling Method:
Liquid-cooled
Coolant Type:
Ethylene glycol-based coolant (50% mixture with distilled water)
Ignition System
Ignition Type:
Electronic ignition (CDI)
Spark Plug Type:
Refer to manual for specific NGK or equivalent part number (e.g., NGK BR9ES)
Variable (CVT), gear reduction ratios provided in manual
Transmission Fluid:
Not applicable for CVT, but drive unit requires specific gear oil (refer to manual for type and capacity)
📐 Dimensions
Exterior
Length:
Refer to manual for exact dimensions
Width:
Refer to manual for exact dimensions
Height:
Refer to manual for exact dimensions
Weights
Dry Weight:
Refer to manual for exact weight (typically around 90-100 kg)
Fuel Tank Capacity:
Refer to manual for exact capacity (typically around 7-8 liters)
Wheels Tires
Front Tire Size:
Refer to manual for exact size (e.g., 130/60-13)
Rear Tire Size:
Refer to manual for exact size (e.g., 140/60-13)
Wheel Bolt Pattern:
Not applicable (scooter specific hub mounting)
🛡️ Safety Features
Ratings
Safety Standards:
Complies with relevant European safety standards for mopeds and scooters.
Active Features
Braking System:
Hydraulic disc brakes front and rear.
Lighting:
Halogen headlight, LED taillight, turn signals.
Passive Features
Chassis Construction:
Steel frame providing a stable and robust platform.
Bodywork:
Aerodynamic fairing for rider protection and stability.
💡 Technology Features
Infotainment
Instrument Cluster:
Digital/analog instrument cluster with speedometer, tachometer, fuel gauge, coolant temperature warning, and indicator lights.
Driver Assistance
Braking Assist:
ABS was not standard on most 2005 SR50 models; manual covers conventional braking system.
Connectivity
Connectivity Features:
No advanced connectivity features typical of modern vehicles; focus is on mechanical and electrical systems.
🔧 Maintenance
Service Intervals
Oil Change Engine:
Refer to manual for specific interval based on mileage or time (typically every 3,000-5,000 km)
Spark Plug Replacement:
Refer to manual for interval (e.g., every 5,000-7,000 km)
Air Filter Cleaning Replacement:
Refer to manual for interval (e.g., every 3,000-5,000 km or as needed based on conditions)
Brake Fluid Change:
Refer to manual for interval (e.g., every 1-2 years)
Transmission Oil Change:
Refer to manual for interval (e.g., every 6,000-10,000 km)
Fluid Specifications
Engine Oil Type:
2-stroke premix oil or automatic injection oil (refer to manual for specific Aprilia-approved type and viscosity, e.g., API TC or JASO FD)
Brake Fluid Type:
DOT 4 hydraulic brake fluid
Coolant Type:
Ethylene glycol-based coolant (50% mixture with distilled water)
Gear Oil Type:
Refer to manual for specific gear oil viscosity (e.g., SAE 80W-90 for gearbox)
Known Issues
Common Problems:
Potential issues can include carburetor clogging, variator wear, electrical connectors, and aging fuel lines. The manual addresses diagnosis and repair for these.
Performance Degradation:
Loss of power or acceleration can be due to worn CVT components, clogged filters, or incorrect fuel/air mixture, all detailed in the manual.
📚 Vehicle History
Brand Heritage
Manufacturer:
Aprilia is an Italian manufacturer with a strong heritage in racing and performance-oriented motorcycles and scooters.
Model Evolution
Sr50 Lineage:
The SR50 line has been a flagship model for Aprilia in the 50cc segment for many years, known for its sporty DNA and frequent updates.
Production
Manufacturing Location:
Primarily manufactured in Italy.
Model Development:
The 2005 model represents a significant iteration, often featuring advancements in styling, engine technology, and chassis components.
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