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APRILIA SR50 SR 50 1992-2011 Service Repair Manual

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🏷️ Basic Information Identification Make: Aprilia Model: SR50 Model Variant: SR 50 Production Years Covered: 1992-2011 Codes Manual Product Code: APRILIA-SR50-92-11-SRM 👋 Introduction Market Position Market Segment: Performance-oriented 50cc scooter segment Target User: Enthusiasts seeking performance and sporty styling in a scooter, often used for urban commuting and recreational riding Competitive Analysis Key Competitors Era: Piaggio Zip SP, Gilera Runner 50, Yamaha Aerox 50, MBK Nitro 50 Key Features Historical Performance: The SR50 was known for its sporty handling and acceleration, often favored by younger riders and tuners Model Variations: Over its production run, the SR50 saw various engine configurations (air-cooled, liquid-cooled) and cosmetic updates across different generations and special editions 📋 Manual Details Coverage Areas Primary Coverage: Comprehensive service and repair for Aprilia SR50 scooters (1992-2011) Intended Audience: Professional technicians and experienced DIY mechanics Page Count Estimated Page Count: 400+ Manual Type Type: Service and Repair Manual Language Language: English Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed diagrams, disassembly/assembly procedures, torque specifications, valve clearance, compression testing Engine Fuel System: Carburetor tuning, fuel pump, fuel filter replacement, fuel line routing Engine Ignition System: Spark plug selection, ignition timing, CDI unit testing, stator and rotor diagnostics Transmission Drive System: CVT operation, variator maintenance, clutch inspection, belt replacement, gear oil specifications Cooling System: Radiator service, coolant type and capacity, water pump inspection, thermostat replacement Electrical System: Wiring diagrams, battery maintenance, charging system (stator, regulator/rectifier), starter motor, lighting circuits, fuses Braking System: Front and rear brake caliper service, master cylinder overhaul, brake fluid type and bleeding procedures, disc and pad replacement Suspension System: Front fork disassembly/rebuild, rear shock absorber replacement, steering head bearing service Wheel And Tire: Tire pressure recommendations, wheel bearing inspection, rim specifications Bodywork And Frame: Panel removal/installation, seat assembly, fairing components, frame inspection Exhaust System: Muffler inspection, exhaust pipe gasket replacement Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug checks, brake pad wear checks, CVT belt inspection Troubleshooting: Diagnostic flowcharts, symptom-based problem identification, electrical fault finding Component Rebuild: Engine overhaul, carburetor rebuilding, brake caliper overhaul, suspension fork servicing Assembly Disassembly: Step-by-step guides for major component removal and installation Electrical Diagnostics: Wiring harness testing, component continuity checks, voltage drop tests Technical Depth Depth Level: Complete workshop level, suitable for full rebuilds and complex diagnostics Detail Level: Highly detailed, with exploded views, schematics, and specific measurements 📊 Manual Specifications File Format File Type: Portable Document Format (PDF) Searchability: Text-searchable, allowing for quick information retrieval Print Quality Resolution: High-resolution scans for clear text and image reproduction Printability: Printable, allowing users to create physical copies of sections or the entire manual Binding Type Digital Binding: N/A (Digital Format) Paper Type Digital Paper: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Type: Two-stroke, single-cylinder Displacement Cc: 49.3 cc (typical for most models) Cooling System: Liquid-cooled (common on later and performance models); some earlier models may be air-cooled Bore X Stroke: e.g., 39.0 mm x 41.4 mm (varies slightly by specific engine variant) Performance Horsepower Hp: Approx. 5.5 - 8.0 HP (depending on year and specific engine tuning) Torque Nm: Approx. 4.5 - 6.0 Nm (depending on year and specific engine tuning) Fuel System Fuel Delivery: Carburetor (e.g., Dell'Orto PHVA 12/14/17.5) Fuel Type: Unleaded gasoline (min. 95 RON recommended) Oil System: Automatic oil injection (separate oil reservoir) 🔧 Transmission Standard Transmission Type: Automatic, Continuously Variable Transmission (CVT) Optional Optional Transmissions: N/A (CVT is standard) Features Drive Type: Belt drive to rear wheel Gear Ratios: Variable (via CVT system), with specific reduction gears Transmission Fluid: Gear oil for final reduction gears (e.g., SAE 80W/90 or specific Aprilia recommendation) 📐 Dimensions Exterior Length Mm: Approx. 1700-1850 mm (varies by generation) Width Mm: Approx. 700-750 mm (varies by generation) Height Mm: Approx. 1100-1200 mm (varies by generation) Weights Dry Weight Kg: Approx. 90-105 kg (depending on model variant and equipment) Gross Vehicle Weight Rating Kg: Approx. 250-270 kg Fuel Tank Capacity Liters: Approx. 5.5 - 7.0 Liters 🛡️ Safety Features Ratings Safety Certification: CE certified for European markets; national homologation varies Active Features Braking System Type: Disc brakes front and rear (hydraulic) Anti Lock Braking System: Optional on some later or higher-spec models (ABS) Passive Features Lighting: Halogen headlight, LED or incandescent taillight and turn signals Mirrors: Adjustable rear-view mirrors 💡 Technology Features Infotainment Dashboard: Analog speedometer, odometer, fuel gauge, coolant temperature gauge (on liquid-cooled models), indicator lights. Driver Assistance ABS: Optional Anti-lock Braking System (ABS) available on select later models. Connectivity Connectivity Features: None (basic scooter design) 🔧 Maintenance Service Intervals Engine Oil Change: Every 3,000 km or annually; check level more frequently. Gear Oil Change: Every 6,000 km or every 2 years. Spark Plug Check Replace: Check every 3,000 km, replace as needed based on wear (recommend NGK BR9ES or similar). Air Filter Cleaning Replace: Clean every 3,000...
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APRILIA SR50 SR 50 1992-2011 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
SR50
Model Variant:
SR 50
Production Years Covered:
1992-2011
Codes
Manual Product Code:
APRILIA-SR50-92-11-SRM
👋 Introduction
Market Position
Market Segment:
Performance-oriented 50cc scooter segment
Target User:
Enthusiasts seeking performance and sporty styling in a scooter, often used for urban commuting and recreational riding
Competitive Analysis
Key Competitors Era:
Piaggio Zip SP, Gilera Runner 50, Yamaha Aerox 50, MBK Nitro 50
Key Features
Historical Performance:
The SR50 was known for its sporty handling and acceleration, often favored by younger riders and tuners
Model Variations:
Over its production run, the SR50 saw various engine configurations (air-cooled, liquid-cooled) and cosmetic updates across different generations and special editions
📋 Manual Details
Coverage Areas
Primary Coverage:
Comprehensive service and repair for Aprilia SR50 scooters (1992-2011)
Intended Audience:
Professional technicians and experienced DIY mechanics
Page Count
Estimated Page Count:
400+
Manual Type
Type:
Service and Repair Manual
Language
Language:
English
Format
Format:
Digital Download (PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Detailed diagrams, disassembly/assembly procedures, torque specifications, valve clearance, compression testing
Engine Fuel System:
Carburetor tuning, fuel pump, fuel filter replacement, fuel line routing
Engine Ignition System:
Spark plug selection, ignition timing, CDI unit testing, stator and rotor diagnostics
Transmission Drive System:
CVT operation, variator maintenance, clutch inspection, belt replacement, gear oil specifications
Cooling System:
Radiator service, coolant type and capacity, water pump inspection, thermostat replacement
Electrical System:
Wiring diagrams, battery maintenance, charging system (stator, regulator/rectifier), starter motor, lighting circuits, fuses
Braking System:
Front and rear brake caliper service, master cylinder overhaul, brake fluid type and bleeding procedures, disc and pad replacement
Suspension System:
Front fork disassembly/rebuild, rear shock absorber replacement, steering head bearing service
Wheel And Tire:
Tire pressure recommendations, wheel bearing inspection, rim specifications
Bodywork And Frame:
Panel removal/installation, seat assembly, fairing components, frame inspection
Exhaust System:
Muffler inspection, exhaust pipe gasket replacement
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, spark plug checks, brake pad wear checks, CVT belt inspection
Troubleshooting:
Diagnostic flowcharts, symptom-based problem identification, electrical fault finding
Component Rebuild:
Engine overhaul, carburetor rebuilding, brake caliper overhaul, suspension fork servicing
Assembly Disassembly:
Step-by-step guides for major component removal and installation
Electrical Diagnostics:
Wiring harness testing, component continuity checks, voltage drop tests
Technical Depth
Depth Level:
Complete workshop level, suitable for full rebuilds and complex diagnostics
Detail Level:
Highly detailed, with exploded views, schematics, and specific measurements
📊 Manual Specifications
File Format
File Type:
Portable Document Format (PDF)
Searchability:
Text-searchable, allowing for quick information retrieval
Print Quality
Resolution:
High-resolution scans for clear text and image reproduction
Printability:
Printable, allowing users to create physical copies of sections or the entire manual
Binding Type
Digital Binding:
N/A (Digital Format)
Paper Type
Digital Paper:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Two-stroke, single-cylinder
Displacement Cc:
49.3 cc (typical for most models)
Cooling System:
Liquid-cooled (common on later and performance models); some earlier models may be air-cooled
Bore X Stroke:
e.g., 39.0 mm x 41.4 mm (varies slightly by specific engine variant)
Performance
Horsepower Hp:
Approx. 5.5 - 8.0 HP (depending on year and specific engine tuning)
Torque Nm:
Approx. 4.5 - 6.0 Nm (depending on year and specific engine tuning)
Fuel System
Fuel Delivery:
Carburetor (e.g., Dell'Orto PHVA 12/14/17.5)
Fuel Type:
Unleaded gasoline (min. 95 RON recommended)
Oil System:
Automatic oil injection (separate oil reservoir)
🔧 Transmission
Standard
Transmission Type:
Automatic, Continuously Variable Transmission (CVT)
Optional
Optional Transmissions:
N/A (CVT is standard)
Features
Drive Type:
Belt drive to rear wheel
Gear Ratios:
Variable (via CVT system), with specific reduction gears
Transmission Fluid:
Gear oil for final reduction gears (e.g., SAE 80W/90 or specific Aprilia recommendation)
📐 Dimensions
Exterior
Length Mm:
Approx. 1700-1850 mm (varies by generation)
Width Mm:
Approx. 700-750 mm (varies by generation)
Height Mm:
Approx. 1100-1200 mm (varies by generation)
Weights
Dry Weight Kg:
Approx. 90-105 kg (depending on model variant and equipment)
Gross Vehicle Weight Rating Kg:
Approx. 250-270 kg
Fuel Tank Capacity Liters:
Approx. 5.5 - 7.0 Liters
🛡️ Safety Features
Ratings
Safety Certification:
CE certified for European markets; national homologation varies
Active Features
Braking System Type:
Disc brakes front and rear (hydraulic)
Anti Lock Braking System:
Optional on some later or higher-spec models (ABS)
Passive Features
Lighting:
Halogen headlight, LED or incandescent taillight and turn signals
Mirrors:
Adjustable rear-view mirrors
💡 Technology Features
Infotainment
Dashboard:
Analog speedometer, odometer, fuel gauge, coolant temperature gauge (on liquid-cooled models), indicator lights.
Driver Assistance
ABS:
Optional Anti-lock Braking System (ABS) available on select later models.
Connectivity
Connectivity Features:
None (basic scooter design)
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 3,000 km or annually; check level more frequently.
Gear Oil Change:
Every 6,000 km or every 2 years.
Spark Plug Check Replace:
Check every 3,000 km, replace as needed based on wear (recommend NGK BR9ES or similar).
Air Filter Cleaning Replace:
Clean every 3,000 km, replace as needed (typically around 6,000-9,000 km).
Cvt Belt Inspection Replace:
Inspect every 3,000 km, replace typically between 6,000-12,000 km depending on wear.
Fluid Specifications
Engine Oil Type:
Fully synthetic 2-stroke engine oil, JASO FD or ISO-L-EGD compliant.
Cooling Fluid Type:
Ethylene glycol-based coolant with anti-corrosion additives, mixed 50/50 with distilled water.
Brake Fluid Type:
DOT 4 brake fluid.
Known Issues
Common Wear Items:
CVT belt, brake pads, suspension bushings, starter motor reliability.
Electrical Gremlins:
Wiring harness degradation and connector corrosion can lead to intermittent electrical faults.
Carburetor Tuning Sensitivity:
These engines can be sensitive to carburetor jetting and setup, requiring periodic adjustment.
📚 Vehicle History
Brand Heritage
Manufacturer:
Aprilia is an Italian manufacturer known for its performance-oriented motorcycles and scooters.
Model Evolution
Generations:
The SR50 model has undergone several significant design and technical updates throughout its lifespan, including engine changes (from air-cooled to liquid-cooled), chassis revisions, and modernizations to styling and features.
Production
Manufacturing Location:
Primarily Italy
🏆 Awards & Recognition
Recognitions
Industry Reputation:
The SR50 is generally well-regarded within the 50cc scooter class for its sporty characteristics and handling.
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