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MANUAL

Aprilia Engine Ditech Electronic


Liquid injection Cooling

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

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Always wear goggles when servicing the brake


GENERAL SAFETY RULES system with brake fluid.
CARBON MONOXIDE Brake fluid is extremely destructive to your eyes.
If you should accidentally get brake fluid in your
If it is necessary to run the engine in order to carry out eyes, flush immediately with a large quantity of
maintenance operation, make sure that the area in wich cool clear water and seek professional medical
you are operating is properly ventilated. assistance immediately.
Never run the engine in enclosed spaces.
If it is necessary to work indoors, use an exhaust KEEP BRAKE FLUID AWAY FROM CHILDREN.
evacuation system.
COOLANT
WARNING
The exhaust fumes contain carbon monoxide, a In certain conditions, the ethylene glycol contained in
poisonous gas that can cause loss of the engine coolant is flammable: its flame is invisible,
consciousness and even death. but you can be burned anyway.

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

WARNING KEEP COOLANT AWAY FROM CHILDREN.


The engine and the components of the exhaust Do not remove the radiator cap when the engine is
system become very hot and remain hot for some hot. The coolant is under pressure and may cause
time after the engine has been stopped. burns.
Before handling these components, wear insulating
gloves or wait until the engine and the exhaust BATTERY HYDROGEN GAS AND ELECTROLYTE
system have cooled down.

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.

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The electrolyte is poisonous. BEFORE DISASSEMBLY


If the electrolyte is accidentally swallowed, drink
large quantities of water or milk and then milk of - Remove any dirt, mud, dust and foreign matter from
magnesia or vegetable oil. the vehicle before disassembling the components.
Seek professional medical attention immediately.
- Use, when necessary, the special tools designed for
KEEP BATTERIES AND ELECTROLYTE AWAY this vehicle.
FROM CHILDREN.
WARNING
PRECAUTIONS AND GENERAL INFORMATION Do not use makeshift tools for any operatio which
calls for a special tool.
Follow with care these recommendations when Failure to heed this warning can lead to serious
repairing disassembling and reassembling the vehicle. personal injury such as when an ill-fitting wrench
slips, and you slam your hand into the workbench
WARNING or a part of the vehicle.
The use of open flames is forbidden for any type
of operation. DISASSEMBLIG THE COMPONENTS
Before commencing any service or inspection
operation on the vehicle, switch off the engine and - Before disconnecting any pipe, cable, etc., mark each
remove the key, wait until the engine and the part with a number or distinguishing mark.
exhaust system have cooled down and, if possible, Each disconnected part must be marked clearly in
raise the vehicle with the suitable equipment onto order that it may be reassembled in the same position
firm flat ground. as it was before disassembly.

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.

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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.

• Press the connectors firmly together, listening for the


typical “click” sound for those connectors provided
with a click tab. Ensure that both halves of the
connectors are firmly pressed together.

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

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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.

Since gasoline expands in the fuel tank when the WARNING


vehicle is sitting in the open sun, never fill the tank Do not add any additives or other substances to
completely to the brim. the gasoline.
Leave at least one inch of expansion space. After refueling, replace the fuel filler cap in the
correct position and make sure that it is properly
Avoid any contact of the fuel with your skin, and closed.
avoid inhalation of fuel vapors.
Use only unleaded gasoline minimum octane rating
Do not ever attempt to siphon fuel from one (M+R)/2 method 90.
container to another using your mouth as suction
for a siphon hose. LUBRIFICANTS

Gasoline is poisonous and carcinogenic and WARNING


contains chemical substances that cause birth Proper vehicle lubrication is critical to safe
defects and other reproductive problems. operation.
If gasoline shoul be accidentally split on the skin Failure to maintain proper lubricant levels or to use
or clothes, immediately wash it off with soap and the proper type of clean, new lubricant, can lead to
water and change clothes. an engine or transmission seizure with subsequent
accident, serious injury or death.
Should you accidentally spill gasoline in your eyes,
flush with a large quantity of water and immediately Use latex gloves for the maintenace operations that
contact a health professional. require contact with used oil.
Used oil may cause skin cancer if repeatedly left
Should you accidentally get gasoline into your in contact with the skin for prolonged periods.
mouth, do not induce vomiting. Although this is unlikely unless you handle used
oil on a daily basis, it is advisable to thoroughly
Drink a large quantity of milk or clear water and wash your hans with soap and water after handling
immediately contact a health professional. used oil.

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.

If your vehicle overturns, it will leak gasoline which

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or ditches, can wet the brakes sufficiently to greatly


CAUTION reduce their effectiveness.
Be very careful when putting oil in your vehicle Failure to heed these warnings may lead to a
not to spill oil. serious accident with consequent risk of serious
Clean up any oil spilled immediately bacause oil injury or even death.
can damage the finish of your vehicle.
Also, oil on the tires creates an extremely slippery The brakes are extremely important for your safety.
and therefore dangerous situation. Do not use the vehicle if the they are neither dirty
nor oily, especially after maintenance operations
In case of lubricant leakage do not ride the vehicle, or inspections.
but check to determine the cause of the leakage
and repair it. Check the brake line, make sure that it is not twisted
or kinked, nor leaking.

ENGINE OIL KEEP AWAY FROM CHILDREN.

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 Oil or other fluid on a disc will contaminate the


Perform these maintenance operations at one-half brake pads.
of the specified intervals, if the vehicle is often used
in rainy or very dusty conditions, or on unpaved Dirty pads must be discarted and replaced, a dirty
roads. or oily disc must be cleanned with a high quality
degreaser.

BRAKES Check the levels of the brake fluid in the reservois


NOTE This vehicle is equipped with front and rear disc at the reguired intervals.
brakes with separate hydraulic systems.
Flush the system and renew all of the brake fluid
The following information may refer to just one braking once every two years.
system but should be observed whith regard to both
brakes. When the pads wear out the brake fluid level in the
reservoir decreases to automatically compensate for
WARNING their wear.
Do not ride the vehicle with worn or malfunctioning The front brake fluid reservoir is located on the right
brakes! The brakes are the most important safety end of the handlebar near the front brake lever.
system of the vehicle, and using the bike with The rear brake fluid reservoir is under the fairing on
brakes that are anything less than perfect is very the right side of the vehicle.
likely to lead to a collision or upset, with
consequent risk of serious injury or death. WARNING
Never use the vehicle if any portion of either brake
Wet conditions seriously degrade the performan- system is leaking.
ce of your brakes.
WARNING
When the road is wet from rain, you should plan DIPOSE OF USED BRAKE FLUID PROPERLY.
to use double the normal stopping distances since
both the brakes themselves and the traction of the KEEP AWAY FROM CHILDREN.
tires on the road are reduced by the presence of
water. When using the fluid, take care not to spill it on
Water on the brakes from washing your vehicle, or the plastic and painted parts, since it damages
splashed up from wet roads, or crossing puddles them.

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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

BE SURE TO KEEP THE DRAINED COOLANT AWAY


-20° 35
FROM CHILDREN AND PETS. 45
-30°
IT IS SWEET TASTING, AS WELL AS EXTREMELY
POISONOUS, AND IS VERY ATTRACTIVE TO -40° 55
CHILDREN AND PATS.
NOTE The characteristics of the various antifreeze
Use extra caution not to spill the coolant on any liquids are different.
hot parts of the engine. It is flammable, and can
emit invisible, noxious fumes. Be sure to read the label on the product to learn the
degree of protection it guarantees.
Always wear rubber or latex gloves when servicing
the cooling system. CAUTION
Use only antifreeze and anticorrosive without ni-
The coolant is made up of 50% water and 50% trite in order to ensure protection at last -35°C.
antifreeze.
This mixture is ideal for most running temperatures
and ensures good protectin against corrosion. TIRES
It is advisable to keep the same mixture also in the hot
season, since in this way losses due to evaporation WARNING
are reduced and it is not necessary to top up very If the tire is inflated to too high a pressure, an
frequently. uncomfrontably harsh ride will result, and riding
The mineral salt deposits left in the radiator by comfort will be compromised.
evaporated water are thus reduced and the efficiency Also, road holding, especially during turns and in
of the cooling system remains unchanged. wet conditions, will likewise be compromised.
If the outdoor temperature is below 0°C, check the
cooling circuit frequently and if necessary increase the If the tire is underinflated (pressure is too low), the
antifreeze concentration (up to maximum 60%). tire may slip on the rim with consequent loss of
contol.
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Again, road holding and handling characteristics


will be degraded, and brake performance will be
reduced.

Insure that all tires are equipped with properly


installed valve caps.

Changing, repairing, maintenance and balancing


operations are very important and should be carried
out by qualified technicians with any kind of rubber
dressing.

Particulary avoid contact to the tire with any


gasoline fluid as this will cause rapid deterioration
of the rubber.

If a tire becomes contaminated with oil or gasoline,


you cannot clean it .

The tire must be replaced.

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.

If a tire should go flat while you are riding the


vehicle, do not attempt to continue riding.
Avoid abrupt braking and steering inputs, and avoid
shutting the throttle quickly.

Slowly decrease the throttle setting, moving to the


side of the road, using the engine compression to
slow you to a stop.

Non-compliance with these instructions may cau-


se accidents with consequent risk of injuries or
even death.

Do not install tires with an inner tube on rims for


tubeless tires, and viceversa.

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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

Variator automatic stepless


Primary V- belt
Gears minimum for stepless change: 2.9
maximum for stepless change: 0.75
Secondary with gears
CAPACITY

Transmission oil 130 cm3

THROTTLE BODY

Type BING
Diffuser Ø18 mm
FUEL FEED

Fuel injector SIEMENS DEKA


Air injector SYNERJECT

IGNITION UNIT

Type of ignition T.C.I.


Pre-ignition Variable: 20° at 3000 rpm 17° at 7500 rpm.

SPARK PLUG

Standard NGK R CPR8-E


Spark plug gap 0,8 - 0,9 mm

ELECTRICAL SYSTEM
Battery 12 V - 4 Ah
Fuses 7,5 A - 15 A
Generator (magneto) 12 V - 140 W

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TIGHTENING TORQUE 50 cc WATER COOLED INJECTION ENGINE


Application Screw TIGHTENING Sealant
TORQUE
Nm Kgm

Pick-up locking M5 x 12 4-6 0,4 - 0,6 no


Stator locking M5 x 25 4-6 0,4 - 0,6 no
Transmission steel plate locking M6 x 12 8 - 12 0,8 - 1,2 Loctite 270
Throttle body (with roller) hose clamp locking end stop end stop no
Suction manifold (built-in, hexagonal) locking M6 x 20 8 - 12 0,8 - 1,2 no
Suction manifold locking, tear-away screws 9 - 11 0,9 - 1,1 no
Transmission cover M6 x 25 8 - 12 0,8 - 1,2 no
Centrifugal clutch cover M6 x 25 8 - 12 0,8 - 1,2 no
Bendix support locking M6 x 30 8 - 12 0,8 - 1,2 no
Starter motor M6 x 25 8 - 12 0,8 - 1,2 no
L/r crankcase locking M6 x 55 8 - 12 0,8 - 1,2 no
M6 x 75
M6 x 100
Wheel bearing retaining plate locking M6 x 16 6 - 10 0,6 - 1,0 Loctite 243
Oil load plug (flanged) M8 x 12 10 - 14 1,0 - 1,4 no
Oil unload (Ch. 8) M6 x 12 5-6 0,5 - 0,6 no
Centrifugal clutch sliding pulley cover locking M4 x 8 2 0,2 no
Head locking (nut) M6 h=9 9 - 11 0,9 - 1,1 no
Clutch locking (nut) M10x1,5 45 - 55 4,5 - 5,5 no
Flywheel locking (nut) M10x1,25 35 - 45 3,5 - 4,5 no
Exhaust stud 4-5 0,4 - 0,5 Loctite 270
Cylinder stud 4-5 0,4 - 0,5 no
Spark plug (thread) M10x1,0 13 - 15 1,3 - 1,5 /
Water outlet unit locking M6 x 20 8 - 12 0,8 - 1,2 no
Flywheel cover locking M6 x 25 8 - 12 0,8 - 1,2 no
Pump cover locking H2O M6 x 25 8 - 12 0,8 - 1,2 no
Breather on water outlet unit (Ch. 8) M6 x 8 8-9 0,8 - 0,9 no
Water unload (Ch. 8) M6 x 8 8-9 0,8 - 0,9 no
Impeller locking M6 x 13 8-9 0,8 - 0,9 no
Joint entrainment screws (special) M6 x 8,5 8 - 12 0,8 - 1,2 no
Compressor screw locking M5 x 20 4-5 0,4 - 0,5 no
Fuel rail screw locking M5 x 20 4-5 0,4 - 0,5 no
Centrifugal clutch fixed pulley locking (nut) M12x1,25 35 - 45 3,5 - 4,5 no
Temperature sensor 20 - 22 2,0 - 2,2 Loctite 572

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TECHNICAL DATA
CYLINDER + PISTON + RINGS

Item: Standard: mm (in) Limit: mm


(in)

Clearance between
piston and cylinder Water 0.035-0.045 0.120
e.i. (0.0014-0.0018) (0.0047)

Piston diam.

Water 40.970-40.985 40.890 min.


e.i. (1.6130-1.6136) (1.6098)
Measure at 23 (0.9) from
the skirt end

Cylinder bore

Water 41.010-41.025 41.105


e.i. (1.6146-1.6152) (1.6183)
Measure at 20 (0.8) from
the top surface

Cylinder distortion - 0.05


(0.002)
0.05
Cylinder head distortion - (0.002)

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CYLINDER + PISTON + RINGS


Item: Standard: Limit:
mm (in) mm (in)

Piston ring gap, ring free


4.5 3.6
Water 1°-2° T Approx.
e.i. (0.18) (0.14)

Piston ring gap, ring assembled into


cylinder Water 0.08 - 0.18 0.80
1°-2° T
e.i. (0.031)
(0.0031 - 0.0071)

Piston ring side clearance Water


0.01 - 0.05 -
e.i. 1°-2°
(0.0004 - 0.0020) -

Piston pin bore in piston


Water 12.002 - 12.010 12.030
e.i. (0.4725 - 0.4728) (0.4736)

Piston pin outside diameter Water


11.996 - 12.000 11.980
e.i. (0.4717)
(0.4723 - 0.4724)

Release 00 / 2001 - 05 Chapter.2 02 / 04


aprilia Water 50 cc e.i.

CONROD + CRANK SHAFT


Item: Standard: Limit:
mm (in) mm (in)

Connecting rod small end diameter


Water 16.003 - 16.011 16.040
e.i. (0.6300 - 0.6304) 36.0 ± 0.05 (0.6315)

Width from crank arm to arm (A)


37.95 - 38.10 -
Water
(1.494 - 1.5) -
e.i.

Misalignment limit (C) 0.03


Measured between two opposite points
(0.001)

Fly wheel to fly wheel width (D)


Water 0.15 - 0.75 -
e.i. (0.0059 - 0.029)

Standard crank width

Release 00 / 2001 - 05 Chapter.2 02 / 05


aprilia Water 50 cc e.i.

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)

Clutch engagement 3500 ± 200 r/min. -

Clutch lock-up 7000 ± 300 r/min. -

THERMOSTAT
Item: Standard: Limit:mm (in)

Thermostat Starts to open at 70° C ± 2° C -

OIL PUMP
Item: Specification:

Inner coil Ri = 26,3 ± 2,6 W a 20° C

TRANSMISSION

Item: Standard: mm (in) Limit: mm (in)

Reduction ratio Variable 2.9 – 0.75 -

Water
Final reduction ratio e.i. 51/15 x 67 x 14 -

Drive belt width 18.4 (0.724) 17.4


(0.685)

Water 104.5
Free lenght spring pulley 110 (4.33) (4.114)
e.i.

Release 00 / 2001 - 05 Chapter.2 02 / 06


aprilia Water 50 cc e.i.

LUBRICANT TABLE

Transmission oil (recommended): F.C.,SAE 75W - 90 or GEAR SYNTH, SAE


75W - 90.
Or other major brand wich meets the specifications of A.P.I. GL-4.

Mixer oil (recommended): GREEN HIT 2 or CITY 2T.


Or other major brand wich meets the specifications of ISO-L-ETC++,A.P.I. TC++

Bearings and other grease points (recommended): AUTOGREASE MP or


GREASE 30
Or other major brand grease for ball bearings with a temperature range of -30 °C
to +140 °C, drop point 150 °C + 230 °C, with good anti-corrosion properties, resistance to
water, and oxidation resistance.

FOR H2O ONLY

Lubricating oil for H2O version


Use only nitrite-free antifreeze in a 50/50 mixture with distilled water.
Recommended engine coolant : ECOBLU - 40 °C or COOL.

Release 00 / 2001 - 05 Chapter.3 03 / 01


aprilia Water 50 cc e.i.

SPECIAL ENGINE TOOLS

US Illustration Tool code Name/function or use

8140229 Engine support.

8140429 Tool for fitting the teflon ring onto the air injector.

8140430 Tool for fitting the teflon ring onto the air injector.

8140431 Air injector extractor.

Release 00 / 2001 - 05 Chapter.4 04 / 01


aprilia Water 50 cc e.i.

SPECIAL ENGINE TOOLS

US Illustration Tool code Name/function or use

8140228 Adapter plate for flywheel and crank shaft extraction.

8140227 Bearing assembly puller

8140225 Reduction gear for crank shaft puller.

8140226 Spacer for crank shaft centering.

Release 00 / 2001 - 05 Chapter.4 04 / 02


aprilia Water 50 cc e.i.

SPECIAL ENGINE TOOLS

US Illustration Tool code Name/function or use

8140488 Fuel-oil-air pressure gauge.

Release 00 / 2001 - 05 Chapter.4 04 / 03


aprilia Water 50 cc e.i.

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).

Tighten the gas-wire adjuster and the return-nut (1) carefully.


If the nut is overtightened, it is possible to damage the threaded pawl plastic seat (2).

Release 00 / 2001 - 05 Chapter.4 04 / 04


aprilia Water 50 cc e.i.

TECHNICAL OBSERVATIONS

MODEL: SR 50 i.e. DITECH

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.

Release 00 / 2001 - 05 Chapter.5 05 / 01


aprilia Water 50 cc e.i.

INJECTION TROUBLESHOOTING

VISUAL ALARMS FOR INJECTION SYSTEM

PRIORITY BULB ACTION


1 (Max) Flashing
2 Stays on
3 Stays off

ACCESS TO “WORKSHOP MODE” FOR CDI 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.

spia di controllo iniezione

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.

Release 00 / 2001 - 05 Chapter.6 06 / 01


aprilia Water 50 cc e.i.

INJECTION TROUBLESHOOTING

DITECH INTERFACE Engine parameters:


The following parameters are displayed:
INSTRUCTIONS
engine rpm, Battery voltage and engine tem-
Connecting the DITECH interface cartridge perature (in º C).
to the scooter:

1 Fit the interface cartridge into the Engine parameters:


GAMEBOY COLOR. Engine rpm: 890
2 Remove the handlebar plate (see fig. 1) Battery voltage: 12.50 V
Engine temp. 78° C.

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.

Italiano Engine history:


English Hours in operation: 15.08 h
Français
Deutsch
Español

Release 00 / 2001 - 05 Chapter.6 06 / 02


aprilia Water 50 cc e.i.

INJECTION TROUBLESHOOTING

Fig. 1

SWITCH
ON/OFF

CROSS-SHAPED KEY ”A”


PUSHBUTTON
KEY ”B”

Release 00 / 2001 - 05 Chapter.6 06 / 03


aprilia Water 50 cc e.i.

INJECTION TROUBLESHOOTING

Cod. 8140181

Pressure gauge (supplied with kit 8140175).

CYLINDER COMPRESSION TEST

- Remove the spark plug;


- Fit the special tool (8140181) with adapter for spark plugs.
- Disconnect wires to the injection system for the air and fuel;
- Open the throttle fully;
- Turn the ignition key to the “ON” position;
- Turn over the starter motor for a few seconds and read off the compression pressure.

COMPRESSION PRESSURE: 6.0 – 6.2 bar (600 kpa)

Release 00 / 2001 - 05 Chapter.6 06 / 04


Prodotto e stampato da Studio Gallo (Engineering) Vicolo Perazzolo,5 35012 Camposampiero (PD) Italy tel / fax 049 - 5794676 www.stgallo.it e-mail: grafica@stgallo.it

aprilia part #8140581 - 05/01 - USA

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