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Aprilia SR 50 1992-2012 Factory Repair Manual

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🏷️ Basic Information Identification Make: Aprilia Model: SR 50 Model Generations Covered: Multiple generations from 1992 to 2012 Applicable Years: 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010, 2011, 2012 Codes Engine Codes: Various Piaggio and Minarelli engines (specific codes vary by year and sub-model, detailed in manual) Chassis Codes: Various (specific codes vary by year and sub-model, detailed in manual) 👋 Introduction Market Position Product Segment: Sport Scooter / High-performance scooter Target Audience: Enthusiasts, performance-oriented riders, owners requiring in-depth maintenance and repair information Competitive Analysis Key Competitors: Yamaha BW's/MBK Booster, Gilera Runner, Piaggio Zip SP, Honda Dio, Malaguti F12 Key Features Vehicle Attributes: Sporty styling, agile handling, powerful (for its class) two-stroke engines, tunable performance potential Manual Value Proposition: Provides comprehensive, factory-authorized repair and maintenance data covering a wide range of model years and potential configurations. 📋 Manual Details Coverage Areas Geographic Coverage: Primarily European and international markets where the SR 50 was sold Language: English (typical for factory service manuals of this era) Manual Type: Factory Service and Repair Manual Page Count Estimated Page Count: Likely 400-800+ pages (comprehensive coverage across 20 years) Format Delivery Format: Downloadable Digital Format (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, disassembly, inspection, repair, top-end (cylinder, piston, rings), bottom-end (crankshaft, connecting rod, bearings), valve timing, cylinder head, cooling system (liquid-cooled variants) Fuel System: Carburetor systems (Dell'Orto, etc.), fuel injection systems (on later models), fuel pump, fuel lines, fuel tank, fuel filters, air filter maintenance Ignition System: CDI ignition, spark plug specifications, ignition coil, stator, wiring diagrams Transmission Drivetrain: Automatic transmission (CVT - Continuously Variable Transmission), clutch, torque converter, drive belt inspection and replacement, gearbox, final drive lubrication Electrical System: Battery maintenance, charging system (alternator/stator), starter motor, lighting system (headlight, taillight, indicators), horn, instrumentation, wiring harnesses, fuses, relays, troubleshooting electrical faults Brakes: Front and rear brake systems (disc brakes), brake pad replacement, brake fluid specifications and bleeding procedures, master cylinder, brake caliper servicing, parking brake (if equipped) Suspension Steering: Front fork (telescopic, possibly upside-down on performance variants), rear shock absorber, swingarm, steering head bearings, wheel alignment, fork oil specifications and change procedures Chassis Bodywork: Frame inspection, body panel removal and installation, seat, handlebars, footpegs, plastics, fairings, decals, center stand, side stand Cooling System: Radiator, coolant specifications, water pump, hoses, thermostat (for liquid-cooled models) Procedures Included Routine Maintenance: Oil changes, filter replacements (air, fuel, oil), spark plug checks, tire pressure, chain lubrication/adjustment (if applicable to specific variants), brake fluid checks, coolant level checks Troubleshooting: Diagnostic flowcharts, common problems and their solutions, electrical fault finding, engine performance issues Major Repairs: Engine rebuilds, transmission overhauls, suspension servicing, brake system overhauls, electrical system repairs Special Tools: Lists of specific tools required for various procedures, torque specifications for all fasteners Torque Specifications: Detailed torque values for engine, chassis, and component fasteners Technical Depth Depth Of Information: Comprehensive factory-level detail, suitable for professional mechanics and advanced DIY enthusiasts Diagnostic Capabilities: Includes detailed diagnostic procedures, wiring diagrams, and troubleshooting trees Rebuild Procedures: Step-by-step instructions for complete engine and component rebuilds 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Searchability: Text-searchable (typically for digital manuals), allowing quick access to information Print Quality Printability: Printable pages for convenient workshop use Binding Type Binding Format: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, two-stroke, single-cylinder (predominantly Piaggio & Minarelli variants) Displacement: Typically 49cc, with some variants or tuning potential for larger displacements (e.g., 70cc kits often used) Performance Horsepower: Approximately 5-7 HP stock, highly variable with tuning and year Torque: Varies, typically around 5-7 Nm stock Fuel System Carburetor Size: Commonly 12mm-17.5mm Dell'Orto PHBN/PHVA or equivalent, depending on year and market Fuel Type: Unleaded gasoline (min 95 octane recommended for performance) Oil Mixture: Autolube system (separate oil reservoir for pre-mixing with fuel), or pre-mix for some specific variants 🔧 Transmission Standard Transmission Type: Automatic CVT (Continuously Variable Transmission) Drive Belt Part Number: Varies by Piaggio/Minarelli engine variant and year; common numbers include Piaggio 839532, Gates 7333 Features Clutch Type: Centrifugal automatic clutch Gear Ratios: Continuously variable, with fixed reduction gears in the final drive housing 📐 Dimensions Exterior Length: Approx. 1750-1850 mm (varies by generation) Width: Approx. 700-750 mm (varies by generation) Height: Approx. 1100-1200 mm (varies by generation) Weights Dry Weight: Approx. 90-110 kg (varies by generation and equipment) Gross Vehicle Weight Rating: Typically around 250-280 kg 🛡️ Safety Features Ratings Crash Test Ratings: N/A (Scooters typically not subjected to same rigorous crash testing as cars) Active Features Braking System: Front and rear disc brakes are standard on most models Passive Features Lighting: Headlight, taillight, brake light, turn signals for visibility 💡 Technology Features Infotainment Instrumentation: Analog speedometer, odometer, fuel gauge, coolant temperature warning light (on...
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SKU: 413803
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Aprilia SR 50 1992-2012 Factory Repair Manual
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
SR 50
Model Generations Covered:
Multiple generations from 1992 to 2012
Applicable Years:
1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010, 2011, 2012
Codes
Engine Codes:
Various Piaggio and Minarelli engines (specific codes vary by year and sub-model, detailed in manual)
Chassis Codes:
Various (specific codes vary by year and sub-model, detailed in manual)
👋 Introduction
Market Position
Product Segment:
Sport Scooter / High-performance scooter
Target Audience:
Enthusiasts, performance-oriented riders, owners requiring in-depth maintenance and repair information
Competitive Analysis
Key Competitors:
Yamaha BW's/MBK Booster, Gilera Runner, Piaggio Zip SP, Honda Dio, Malaguti F12
Key Features
Vehicle Attributes:
Sporty styling, agile handling, powerful (for its class) two-stroke engines, tunable performance potential
Manual Value Proposition:
Provides comprehensive, factory-authorized repair and maintenance data covering a wide range of model years and potential configurations.
📋 Manual Details
Coverage Areas
Geographic Coverage:
Primarily European and international markets where the SR 50 was sold
Language:
English (typical for factory service manuals of this era)
Manual Type:
Factory Service and Repair Manual
Page Count
Estimated Page Count:
Likely 400-800+ pages (comprehensive coverage across 20 years)
Format
Delivery Format:
Downloadable Digital Format (PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, disassembly, inspection, repair, top-end (cylinder, piston, rings), bottom-end (crankshaft, connecting rod, bearings), valve timing, cylinder head, cooling system (liquid-cooled variants)
Fuel System:
Carburetor systems (Dell'Orto, etc.), fuel injection systems (on later models), fuel pump, fuel lines, fuel tank, fuel filters, air filter maintenance
Ignition System:
CDI ignition, spark plug specifications, ignition coil, stator, wiring diagrams
Transmission Drivetrain:
Automatic transmission (CVT - Continuously Variable Transmission), clutch, torque converter, drive belt inspection and replacement, gearbox, final drive lubrication
Electrical System:
Battery maintenance, charging system (alternator/stator), starter motor, lighting system (headlight, taillight, indicators), horn, instrumentation, wiring harnesses, fuses, relays, troubleshooting electrical faults
Brakes:
Front and rear brake systems (disc brakes), brake pad replacement, brake fluid specifications and bleeding procedures, master cylinder, brake caliper servicing, parking brake (if equipped)
Suspension Steering:
Front fork (telescopic, possibly upside-down on performance variants), rear shock absorber, swingarm, steering head bearings, wheel alignment, fork oil specifications and change procedures
Chassis Bodywork:
Frame inspection, body panel removal and installation, seat, handlebars, footpegs, plastics, fairings, decals, center stand, side stand
Cooling System:
Radiator, coolant specifications, water pump, hoses, thermostat (for liquid-cooled models)
Procedures Included
Routine Maintenance:
Oil changes, filter replacements (air, fuel, oil), spark plug checks, tire pressure, chain lubrication/adjustment (if applicable to specific variants), brake fluid checks, coolant level checks
Troubleshooting:
Diagnostic flowcharts, common problems and their solutions, electrical fault finding, engine performance issues
Major Repairs:
Engine rebuilds, transmission overhauls, suspension servicing, brake system overhauls, electrical system repairs
Special Tools:
Lists of specific tools required for various procedures, torque specifications for all fasteners
Torque Specifications:
Detailed torque values for engine, chassis, and component fasteners
Technical Depth
Depth Of Information:
Comprehensive factory-level detail, suitable for professional mechanics and advanced DIY enthusiasts
Diagnostic Capabilities:
Includes detailed diagnostic procedures, wiring diagrams, and troubleshooting trees
Rebuild Procedures:
Step-by-step instructions for complete engine and component rebuilds
📊 Manual Specifications
File Format
File Type:
PDF (Portable Document Format)
Searchability:
Text-searchable (typically for digital manuals), allowing quick access to information
Print Quality
Printability:
Printable pages for convenient workshop use
Binding Type
Binding Format:
N/A (Digital Download)
Paper Type
Paper Quality:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, two-stroke, single-cylinder (predominantly Piaggio & Minarelli variants)
Displacement:
Typically 49cc, with some variants or tuning potential for larger displacements (e.g., 70cc kits often used)
Performance
Horsepower:
Approximately 5-7 HP stock, highly variable with tuning and year
Torque:
Varies, typically around 5-7 Nm stock
Fuel System
Carburetor Size:
Commonly 12mm-17.5mm Dell'Orto PHBN/PHVA or equivalent, depending on year and market
Fuel Type:
Unleaded gasoline (min 95 octane recommended for performance)
Oil Mixture:
Autolube system (separate oil reservoir for pre-mixing with fuel), or pre-mix for some specific variants
🔧 Transmission
Standard
Transmission Type:
Automatic CVT (Continuously Variable Transmission)
Drive Belt Part Number:
Varies by Piaggio/Minarelli engine variant and year; common numbers include Piaggio 839532, Gates 7333
Features
Clutch Type:
Centrifugal automatic clutch
Gear Ratios:
Continuously variable, with fixed reduction gears in the final drive housing
📐 Dimensions
Exterior
Length:
Approx. 1750-1850 mm (varies by generation)
Width:
Approx. 700-750 mm (varies by generation)
Height:
Approx. 1100-1200 mm (varies by generation)
Weights
Dry Weight:
Approx. 90-110 kg (varies by generation and equipment)
Gross Vehicle Weight Rating:
Typically around 250-280 kg
🛡️ Safety Features
Ratings
Crash Test Ratings:
N/A (Scooters typically not subjected to same rigorous crash testing as cars)
Active Features
Braking System:
Front and rear disc brakes are standard on most models
Passive Features
Lighting:
Headlight, taillight, brake light, turn signals for visibility
💡 Technology Features
Infotainment
Instrumentation:
Analog speedometer, odometer, fuel gauge, coolant temperature warning light (on liquid-cooled models), indicator lights.
Driver Assistance
ABS:
ABS was not a standard feature on most SR 50 models within this period, though some very late or special editions might have offered it.
Connectivity
Diagnostic Ports:
Some later models might feature basic OBD-II or proprietary diagnostic connectors for electronic fault diagnosis, detailed in the manual.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 3,000-5,000 km or annually (check manual for specific year)
Gearbox Oil Change:
Every 6,000-10,000 km (check manual for specific year)
Drive Belt Inspection:
Every 5,000-8,000 km, replacement usually around 10,000-15,000 km
Fluid Specifications
Engine Oil:
2-stroke semi-synthetic or fully synthetic oil (API TC, JASO FD certified), specific grade usually SAE 10W-30 for gearbox oil
Coolant:
Ethylene glycol-based antifreeze (e.g., Motul Motocool Expert, Castrol Radicool) mixed with distilled water at 50/50 ratio
Brake Fluid:
DOT 4 or DOT 3 brake fluid (check manual for specific requirement)
Known Issues
Common Problems:
Worn drive belts, clutch issues, carburetor jetting problems, electrical connector corrosion, exhaust de-coking (two-stroke engines), suspension wear.
Tuning Considerations:
Commonly modified with performance exhaust systems, carburetors, variators, and ignition components, requiring careful tuning.
📚 Vehicle History
Brand Heritage
Manufacturer:
Aprilia is an Italian manufacturer known for its performance motorcycles and scooters.
Model Evolution
Generations:
The SR 50 has seen numerous iterations, including the SR 50 Stealth, SR 50 Funmaster, SR 50 Factory, and various other special editions, often utilizing Piaggio or Minarelli engines as platform bases.
Production
Manufacturing Location:
Primarily Italy
🏆 Awards & Recognition
Recognitions
Model Accolades:
The Aprilia SR 50 has historically been recognized for its sporty performance and handling in the scooter segment.
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