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QUICK WORKSHOP
MANUAL
1050 1
aprilia Water 50 cc e.i.
CONTENTS INTRODUCTION
- This manual contains information for carrying out
routing maintenance and repair on the Ditech engine
and transmission unit.
General safety rules 1 - The information and diagrams in the manual are up-
to-date at the time of publication.
- This publication is intended for use by Aprilia dealers
and their trained mechanics. A large number of
Technical data procedures do not require explanation and therefore
2 have been omitted. It has not been possible to give
detailed mechanical data for every procedure. All
personnel using this manual must therefore possess
the basic skills of motorcycle mechanics and be
Lubrication table 3 thoroughly familiar with motorcycle repair procedures.
Without these skills and familiarity, it is likely that any
repair or maintenance operation carried out will be
ineffective, and may even lead to a dangerous
condition.
Special engine tools 4 Since it is not possible to provide detailed description
for all procedures, the user of this manual is cautioned
to take special care in performing any repair or
maintenance operation in order to prevent damage to
Technical notes 5 the engine and transmission, or injury to the rider or
mechanic.
Since Aprilia s.p.a. constantly strives to improve its
products and documentation, this manual may not be
Injection troubleshooting 6 up to date. All impor tant technical change to
maintenance and repair procedures are provided to
all Aprilia s.p.a. authorized dealers, sales agents, and
distributors world wide. As these changes accumula-
Disassembly/ te, they will be included in later editions of this manual.
Reassembly sequence 7 Always ensure that before you attempt any repair or
maintenace operation, that you have considered the
latest technical data from Aprilia s.p.a.
If you have questions or comments about the
procedures described in this manual, please contact
the Aprilia Consumer Service Department, who will be
pleased to give you all the information and explanations
you require, and to bring you up to date with any
changes.
For further information see:
- SPARE PARTS CATALOGUE no. 553Y
Produced by
Training and Documentation Department
aprilia s.p.a. Aprilia s.p.a. reserves the right to carry out any
via G. Galilei, 15 - 30033 Noale (VE) - Italia modification to any of its models, without notice, at
Tel. +39 - 041 57 86 101
Fax + 39 - 041 57 86 100 any time.
www.serviceaprilia.com Unauthorized electronic retrieval or reproduction of any
www.aprilia.com
part of this manual is unlawful in all countries. Products
or services manufactured or provided by third parties
Produced and printed by
Studio Gallo (Engineering)
are quoted merely as examples and do not constitute
Vicolo Perazzolo, 5 a recommendation; Aprilia s.p.a. is not liable for the
35012 Camposampiero (PD) performance or use of such products and services.
tel. 049 - 5794676
fax.049 - 5794676
Italy First edition. May 2001.
www.stgallo.it
e-mail: grafica@stgallo.it
GASOLINE WARNING
Avoid spilling the engine coolant on the exhaust
Work in a well ventilated area. system or on the engine components.
Keep cigarettes, flames or sparks away from the work They may be hot enough to cause the coolant to
area and from the place where gasoline is stored. ignite and burn whitout a visible flame.
The coolant (ethylene glycol) can cause skin
WARNING irritation and is poisonous if swallowed.
Gasoline is extremely flammable and becoms
explosive under certain conditions. Engine coolant is sweet tasting, and therefore
extremely attractive to pets and other animals, as
KEEP GASOLINE AWAY FROM CHILDREN. well as being extremely toxic.
Do not leave coolant in an open container where
animals may be able to drink it.
HOT COMPONENTS
USED ENGINE OIL AND FORK OIL The battery gives off explosive gases; keep
cigarettes, flames and sparks away from the
WARNING battery.
Use latex gloves for the maintenance operations Provide adequate ventilation when operating or
that require contact with used oil. recharging the battery.
Used oil may cause skin cancer if repeatedly left
in contact with the skin for prolonged periods. The battery contains sulphuric acid (electrolyte).
Although this is unlikely unless you handle used Contact with the skin or the eyes may cause serious
oil on a daily basis, it is advisable to thoroughly burns.
wash your hans with soap and water after handling
used oil. Always wear tight fitting goggles and protective
clothing when handling battery electrolyte.
KEEP OIL AWAY FROM CHILDREN. It is particularly important for you to protect your
eyes, since even a minuscule amount of battery
BRAKE FLUID acid can destroy your vision.
Should you accidentally get even the smallest
CAUTION amount of battery acid on your skin or eyes,
The brake fluid can damage painted, plastic or immediately flush with large quantities of clear cool
rubber parts. When performing maintenance water and immediately seek professional medical
operations on the breaking system, place a clean attention.
shop towel on these parts.
In order to avoid burns, be careful not to touch any - Clean and carefully wash all disassembled parts with
parts of the engine or exhaust system which have fireproof solvent or a nonflammable detergent.
not cooled down completely.
- Keep maiting parts together, since they have worn in
The brakes also get quite hot in operation. during normal use. There are some sets of parts,
Be sure that the brakes have cooled thoroughly before such as front sprocket, chain, and rear wheel
beginning any service operations. sprocket, which all must be replaced as a set.
Avoid the templation to hold any hardware or other - Be careful not to place plastic or painted parts close
part of the vehicle in your mouth while working on to heat sources, where they might be damaged.
the vehicle.
REASSEMBLING THE COMPONENTS
No part of the motorscooter is edible and some of
the coatings, plastics, and platings, etc. are CAUTION
noxious if not outright toxic. Never use a circlip twice. When a circlip is removed,
it must be replaced with a new one.
If not expressly described, the reassembly of the When assembling a new circlip be careful not to
units is carried out by reversing the order of stretch its ands more than strictly necessary to
operations. place it on the shaft.
Handle fuel with the greatest cleaning. After installing a circlip, make sure that it is
completely and firmly inserted in its seat.
See gasoline warning.
Never use fuel as a solvent for cleaning the vehicle. Do not use compressed air to clean the bearings.
Disconnect the negative cable (-) from the battery NOTE The bearings must rotate freely, without halting
when electric welding. or noise otherwise they must be replaced.
When two or more persons are working together, - Use only aprilia SPARE PARTS.
make sure that each is working in safe conditions. - Use the recommended lubricants.
- Always lubricate parts before reassembly.
Be sure that all the mechanics working on any one - When tightening screws, nuts, and bolts, start with
vehicle are thoroughly briefed as wath each will the largest diameter fasteners.
be doing, and insure that one mechanic is When several fasteners are arranged in a pattern,
responsible for insuring that all safety related start with the innermost fasteners, and tighten
items, such as tightening torques, are properly diagonally across the pattern.
considered.
Tighten each fastener successively before applying regularly, and always use a torque wrench
the final tightening torque. reinstalling them.
- Always replace gaskets, grommets, circlips, O-rings Failure to comply with this warning could allow
and split pins (cotter pins) with new ones. one of these components to be lost which could
Before assembling, clean all mating surfaces lock a wheel or cause other handling problems with
carefully, removing all traces of the old gasket and consequent overturning and risk of serious injury
gasket sealing compound. or even death.
Also carefully clean any oil seal you plan to reuse.
It is recommended that all oil seals be replaced each The table below shows tightening torques for screws
time they are disassembled. and bolts with metric ISO threads, as is used in this
Gaskets should never be reused. vehicle. These are general values to be used if no
Apply a thin film of lithium based grease to all oil specific value is given in this manual or other aprilia
seals before assembling. service literature.
Install oil seals and bearings with the identification
mark or serial number facing outward (visible). Screw or Tightening torque
Wrench
Copiously lubricate bearings before installation and bolt thread ftlb (Nm)
before assembly.
- Make sure that each component has been M6 10 4.34 6
reassembled correctly.
- After any repair or periodic maintenance operation
M8 12 10.84 15
is carried out, the vehicle must be test ridden in an 14 21.70 30
M 10
area away from traffic and other hazards.
M 12 17 39.79 55
ELECTRICAL CONNECTORS
M 14 19 61.49 85
The electrical connectors must be disconnected as
follows. Faiture to follow these procedures will M 16 22 94.03 130
irreparably damage the connector and wiring.
• Press in the click tab. If not otherwise indicated, the tightening torques shown
should be used for clean and dry threads, at room
CAUTION temperature.
Do not pull the cables to disconnect the two NOTE To avoid damage to the threads, tighten
connectors. screws and bolts as follows:
• Grasp the two connectors and disconnect them by
pulling in opposite directions. • Run up the fasteners finger tight.
• If dirt, rust, dust or moisture is seen on the connector, • Applying half the prescribed tightening torque, tighten
blow out the connector with air. the fasteners that are diametrically opposite each
• Make sure that the cables are correctly crimped to other.
the terminals placed inside the connectors. • Repeat, applying the prescribed tightening torque.
NOTE The two halves of the connector fit together NOTE In this way the pressure exerted by the
properly in only one orientation. Ensure that the fastening elements will be uniformly distributed on the
connector is properly aligned before attempting to joint surface.
assmble it.
TIGHTENING TORQUES
WARNING
Remember that the tightening torque of all
fasteners on the wheels, brakes, axles, and other
components of the suspension system is very
important to ensure the safety of the vehicle, and
must be kept at the prescribed values.
Check the tightening torque of the fasteners
is extremely flammable.
SPECIFIC SAFETY RULES
FUEL Flames or sparks may ignite this which will not
only destroy the vehicle but also could do serious
WARNING property damage to surrounding property and cau-
Gasoline is extremely flammable and in some se serious injuries or even death.
conditions can become explosive.
Therefore, it is necessary to refuel and carry out ALWAYS KEEP GASOLINE AWAY FROM
maintenance operations involving the fuel system CHILDREN.
in a well-ventilated area with the engine off.
Do not refuel or do any maintenance on the fuel DISPOSE OF UNWANTED GASOLINE PROPERLY,
system with the engine running. DO NOT DUMP IT INTO STORM SEWERS OR INTO
Do not smoke while refueling or near fuel vapors. A SINK OR TOILET.
Never allow any portion of the fuel system to come
in contact with open flames, sparks or other heat CAUTION
sources. Before opening the fuel filler cap, if necessry, clean
the it cap and the part around it with a clean cloth.
Be careful to avoid spilling fuel when you are Prevent any foreign material from getting into the
refueling. Spilleng fuel could ignite when it fuel tank, this could lead to serious engine damage.
contacts hot engine or exhaust system surfaces.
If you use any container or funnel for refueling,
If you accidentally spill some fuel, make sure that make sure that it is perfectly clean.
it is wiped up or completely evaporated before Any foreign matter getting into the fuel tank may
starting the vehicle. lead to severe damage.
Never try to siphon gasoline by sucking it with your KEEP OIL AWAY FROM CHILDREN.
mouth.
DISPOSE OF OIL PROPERLY.
Use a manual pump or a similar system.
WARNING
If the engine oil pressure warning light LED remains DISC BRAKES
on (when the engine is running), or if it comes on
during the normal running of the engine, this means WARNING
that the oil system is not developing sufficient The brakes are the most important safety system
pressure. on your vehicle.
For your safety, they must be in perfect repair, so
Failure to head this warning can lead to engine they should be checked every time you ride the
seizure, upset, and serious injury or even death. vehicle.
CAUTION CAUTION
To avoid serious damage to the system, do not use Use only distilled water when topping off the
fluids other than the recommended ones nor mix cooling system. This will reduce damage to the
different fluids for topping up. engine.
Do not use brake fluid taken from old or aiready
opened containers.
WARNING
CAUTION The coolant is very hot.
Do not use the vehicle if the coolant is below the
minimum prescribed level. Do not remove the filler cap when the engine is
hot sice the coolant is under pressure and it will
WARNING splash out violently.
Coolant is poisonous! Do not ingest coolant under
any circumstance. If it gets in contact with the skin or with your
Should you get coolant in your mouth, rinse with clothing, it may cause severe burns.
cool water and immediately seek medical attention.
Coolant is also very dangerous to your skin and WARNING
eyes. Be aware of the risk of burns from the coolant.
Should you accidentally get coolant on your Check the coolant level and top up the expansion
clothing or skin, change clothers immediately. tank only after the engine thoroughly cooled.
Wash coolant from your skin with hot water and
soap. Do not use your finges or any other object to check
Should you get coolant in your eyes, flush with if there is enough coolant.
plenty of cool water and seek professional medical
help at once. On the basis of the desired freezing temeperature of
Should someone swallow coolant accidentally, in- the coolant mixture, add to the water the percentage
duce vomiting, rinse mouth with water, and of coolant indicated in the following table:
immediately seek professional medical attention.
Freezing point Coolant
DISPOSE OF THE COOLANT PROPERLY. °C of the volume
WARNING
Some of the original equipment tires for this vehicle
are provided with wear indicators.
There are several kinds of wear indicators.
Contact your dealer to get the necessary informa-
tion on the wear check procedures.
Visually check the tire wear and if they are worn,
have them replaced.
TECHNICAL DATA
ENGINE
Type water/injection
Engine type Liquid cooled with direct fuel injection
Number of valves -
Number of cylinders single cylinder, horizontal
Piston displacement 49,38 cm3
Bore/Stroke 41,0 mm / 37,4 mm
Corrected compression ratio rc = 12,3 ± 0,5
Idle rpm 1500 ± 50 r/min
Starter system electric
Clutch centrifugal
Gearbox automatic stepless centrifugal clutch
Lubrication system Electric oil pump
Cooling system Liquid
TRANSMISSION
THROTTLE BODY
Type BING
Diffuser Ø18 mm
FUEL FEED
IGNITION UNIT
SPARK PLUG
ELECTRICAL SYSTEM
Battery 12 V - 4 Ah
Fuses 7,5 A - 15 A
Generator (magneto) 12 V - 140 W
TECHNICAL DATA
CYLINDER + PISTON + RINGS
Clearance between
piston and cylinder Water 0.035-0.045 0.120
e.i. (0.0014-0.0018) (0.0047)
Piston diam.
Cylinder bore
CLUTCH
Item: Standard: mm (in) Limit:mm (in)
Clutch wheel inner diameter 110.00 - 110.15 110.50
(4.331 - 4.337) (4.350)
3.0 2.0
Clutch shoe thickness (0.12) (0.08)
THERMOSTAT
Item: Standard: Limit:mm (in)
OIL PUMP
Item: Specification:
TRANSMISSION
Water
Final reduction ratio e.i. 51/15 x 67 x 14 -
Water 104.5
Free lenght spring pulley 110 (4.33) (4.114)
e.i.
LUBRICANT TABLE
8140429 Tool for fitting the teflon ring onto the air injector.
8140430 Tool for fitting the teflon ring onto the air injector.
REED VALVE
Measure the clearance (A) between the reed valve and its seat.
If clearance (A) is in excess of 0.2 mm (.08 in), replace the reed valve. Measure distance (B).
(B) should be at least 1 mm (.04 in).
TECHNICAL OBSERVATIONS
Battery connection
Information:
Use the utmost care when connecting the battery to the Ditech SR 50 i.e. scooter. Applying
reverse polarity to the CDI unit will destroy the CDI unit.
CDI units thus damaged are not covered by warrenty.
On delivery
Problem arising:
Newly delivered vehicles may have fouled spark plugs, and the engine may therefore start to
miss after idling for just a short time. In order to rectify this problem, after carrying out all new
vehicle receiving operations, start up the engine and ride the scooter for a few kilometers at
high RPM to remove any excess oil left in the cylinder by the production process. This will
eliminate spark plug fouling.
Solution:
After carrying out all specified goods-in operations, start up the engine and ride the scooter for
a few km, at high revs, to remove any excess oil used for production purposes. This will clear
up any spark plug fouling.
INJECTION TROUBLESHOOTING
1 With the engine off, and ignition key in the “OFF” position, open the throttle fully.
2 With the throttle held full open, turn the ignition key to “ON” without starting the engine.
The red led for the injection inspection comes on 2 seconds, then goes off.
3 Keep the throttle turned fully open and wait for the red led to come on again. Release the
throttle within 3 seconds of the red led coming on. During this time the led will stay on.
4 When the throttle is released the red led starts to flash. The number of times it flashes
shows the fault. For example, if the led flashes 10 times, it means there is a problem with
the fuel pump (see TABLE OF FAULT CODES)
5 When the led has been off for 4 seconds, the first code sequence has terminated.
6 If there are further faults, the led comes back on for 4 seconds, then flashes, and so on. For
example, after 10 flashes (fuel pump) and after coming on for 4 seconds, the led flashes 12
times: this means there is also a fuel injector fault (see TABLE OF FAULT CODES).
7 The sequences end when the first fault is repeated. In our example, if after 10 then 12
flashes the led goes back to 10, it means there are only 2 faults (fuel pump and fuel injector).
8 If the ignition key is not turned to the “OFF” position, the complete sequence of faults is
repeated 4 times, after which time the CDI cancels the fault memory. In our example we
have the following sequence: [10 – 12] – [10 – 12] – [10 – 12] – [10 – 12] then cancel.
INJECTION TROUBLESHOOTING
Injection parameters:
The engine parameters displayed on the
3 Connect the interface cartridge to the 3- screen refer to: engine rpm, percentage of
way socket under the handlebar plate, throttle opening (0 – 100%), ignition advance
using a suitable adapter (in degrees) and engine condition. Engine
condition is given with the following words:
off, starting, on, ticking over or cut-off.
Use of the DITECH interface cartridge
The software for the DITECH interface
cartridge is structured so that all functions
Injection parameters:
can be selected easily. Engine rpm: 9150
Switch on the Gameboy with the ON/OFF Throttle valve 74%
Pre-ignition 6° C.
switch (see Fig).
Engine condition: on
To scroll the menu, use the UP and DOWN
keys on the cross-shaped pushbutton.
Press A to confirm and B to return to the
previous menu.
The following functions can be selected:
Engine history:
Language Selection: This displays the number of hours the engine
A list of languages has been in operation.
INJECTION TROUBLESHOOTING
Fig. 1
SWITCH
ON/OFF
INJECTION TROUBLESHOOTING
Cod. 8140181