Ditech Water Cooled Part1

aprilia

QUICK WORKSHOPMANUAL

Aprilia Engine Ditech ElectronicLiquid injection Cooling

1050 1

aprilia Water 50 cc e.i.

Release 00 / 2001 - 05

General safety rules 1

2

3

44

5

7

Technical data

Lubrication table

Special engine tools

Produced byTraining and Documentation Departmentaprilia s.p.a.via G. Galilei, 15 - 30033 Noale (VE) - ItaliaTel. +39 - 041 57 86 101Fax + 39 - 041 57 86 100www.serviceaprilia.comwww.aprilia.com

Produced and printed byStudio Gallo (Engineering)Vicolo Perazzolo, 535012 Camposampiero (PD)tel. 049 - 5794676fax.049 - 5794676Italywww.stgallo.ite-mail: [email protected]

INTRODUCTIONCONTENTS

- This manual contains information for carrying outrouting maintenance and repair on the Ditech engineand transmission unit.- The information and diagrams in the manual are up-to-date at the time of publication.- This publication is intended for use by Aprilia dealersand their trained mechanics. A large number ofprocedures do not require explanation and thereforehave been omitted. It has not been possible to givedetailed mechanical data for every procedure. Allpersonnel using this manual must therefore possessthe basic skills of motorcycle mechanics and bethoroughly familiar with motorcycle repair procedures.Without these skills and familiarity, it is likely that anyrepair or maintenance operation carried out will beineffective, and may even lead to a dangerouscondition.Since it is not possible to provide detailed descriptionfor all procedures, the user of this manual is cautionedto take special care in performing any repair ormaintenance operation in order to prevent damage tothe engine and transmission, or injury to the rider ormechanic.Since Aprilia s.p.a. constantly strives to improve itsproducts and documentation, this manual may not beup to date. All important technical change tomaintenance and repair procedures are provided toall Aprilia s.p.a. authorized dealers, sales agents, anddistributors world wide. As these changes accumula-te, they will be included in later editions of this manual.Always ensure that before you attempt any repair ormaintenace operation, that you have considered thelatest technical data from Aprilia s.p.a.If you have questions or comments about theprocedures described in this manual, please contactthe Aprilia Consumer Service Department, who will bepleased to give you all the information and explanationsyou require, and to bring you up to date with anychanges.For further information see:- SPARE PARTS CATALOGUE no. 553Y

Aprilia s.p.a. reserves the right to carry out anymodification to any of its models, without notice, atany time.Unauthorized electronic retrieval or reproduction of anypart of this manual is unlawful in all countries. Productsor services manufactured or provided by third partiesare quoted merely as examples and do not constitutea recommendation; Aprilia s.p.a. is not liable for theperformance or use of such products and services.

First edition. May 2001.

01 / 01Chapter.1

Disassembly/Reassembly sequence

Technical notes

6Injection troubleshooting


Release 00 / 2001 - 05

CARBON MONOXIDE

If it is necessary to run the engine in order to carry outmaintenance operation, make sure that the area in wichyou are operating is properly ventilated.Never run the engine in enclosed spaces.If it is necessary to work indoors, use an exhaustevacuation system.

The exhaust fumes contain carbon monoxide, apoisonous gas that can cause loss ofconsciousness and even death.

GASOLINE

Work in a well ventilated area.Keep cigarettes, flames or sparks away from the workarea and from the place where gasoline is stored.

Gasoline is extremely flammable and becomsexplosive under certain conditions.

KEEP GASOLINE AWAY FROM CHILDREN.

HOT COMPONENTS

The engine and the components of the exhaustsystem become very hot and remain hot for sometime after the engine has been stopped.Before handling these components, wear insulatinggloves or wait until the engine and the exhaustsystem have cooled down.

USED ENGINE OIL AND FORK OIL

Use latex gloves for the maintenance operationsthat require contact with used oil.Used oil may cause skin cancer if repeatedly leftin contact with the skin for prolonged periods.Although this is unlikely unless you handle usedoil on a daily basis, it is advisable to thoroughlywash your hans with soap and water after handlingused oil.

KEEP OIL AWAY FROM CHILDREN.

BRAKE FLUID

The brake fluid can damage painted, plastic orrubber parts. When performing maintenanceoperations on the breaking system, place a cleanshop towel on these parts.

01 / 02Chapter.1

WARNING

WARNING

WARNING

WARNING

CAUTION

Always wear goggles when servicing the brakesystem with brake fluid.Brake fluid is extremely destructive to your eyes.If you should accidentally get brake fluid in youreyes, flush immediately with a large quantity ofcool clear water and seek professional medicalassistance immediately.

KEEP BRAKE FLUID AWAY FROM CHILDREN.

COOLANT

In certain conditions, the ethylene glycol contained inthe engine coolant is flammable: its flame is invisible,but you can be burned anyway.

Avoid spilling the engine coolant on the exhaustsystem or on the engine components.They may be hot enough to cause the coolant toignite and burn whitout a visible flame.The coolant (ethylene glycol) can cause skinirritation and is poisonous if swallowed.

Engine coolant is sweet tasting, and thereforeextremely attractive to pets and other animals, aswell as being extremely toxic.Do not leave coolant in an open container whereanimals may be able to drink it.

KEEP COOLANT AWAY FROM CHILDREN.

Do not remove the radiator cap when the engine ishot. The coolant is under pressure and may causeburns.

BATTERY HYDROGEN GAS AND ELECTROLYTE

The battery gives off explosive gases; keepcigarettes, flames and sparks away from thebattery.Provide adequate ventilation when operating orrecharging the battery.

The battery contains sulphuric acid (electrolyte).Contact with the skin or the eyes may cause seriousburns.

Always wear tight fitting goggles and protectiveclothing when handling battery electrolyte.It is particularly important for you to protect youreyes, since even a minuscule amount of batteryacid can destroy your vision.Should you accidentally get even the smallestamount of battery acid on your skin or eyes,immediately flush with large quantities of clear coolwater and immediately seek professional medicalattention.

WARNING

GENERAL SAFETY RULES


Release 00 / 2001 - 05 01 / 03Chapter.1

The electrolyte is poisonous.If the electrolyte is accidentally swallowed, drinklarge quantities of water or milk and then milk ofmagnesia or vegetable oil.Seek professional medical attention immediately.

KEEP BATTERIES AND ELECTROLYTE AWAYFROM CHILDREN.

PRECAUTIONS AND GENERAL INFORMATION

Follow with care these recommendations whenrepairing disassembling and reassembling the vehicle.

The use of open flames is forbidden for any typeof operation.Before commencing any service or inspectionoperation on the vehicle, switch off the engine andremove the key, wait until the engine and theexhaust system have cooled down and, if possible,raise the vehicle with the suitable equipment ontofirm flat ground.

In order to avoid burns, be careful not to touch anyparts of the engine or exhaust system which havenot cooled down completely.

The brakes also get quite hot in operation.Be sure that the brakes have cooled thoroughly beforebeginning any service operations.

Avoid the templation to hold any hardware or otherpart of the vehicle in your mouth while working onthe vehicle.

No part of the motorscooter is edible and some ofthe coatings, plastics, and platings, etc. arenoxious if not outright toxic.

If not expressly described, the reassembly of theunits is carried out by reversing the order ofoperations.Handle fuel with the greatest cleaning.

See gasoline warning.Never use fuel as a solvent for cleaning the vehicle.

Disconnect the negative cable (-) from the batterywhen electric welding.

When two or more persons are working together,make sure that each is working in safe conditions.

Be sure that all the mechanics working on any onevehicle are thoroughly briefed as wath each willbe doing, and insure that one mechanic isresponsible for insuring that all safety relateditems, such as tightening torques, are properlyconsidered.

WARNING

BEFORE DISASSEMBLY

- Remove any dirt, mud, dust and foreign matter fromthe vehicle before disassembling the components.

- Use, when necessary, the special tools designed forthis vehicle.

Do not use makeshift tools for any operatio whichcalls for a special tool.Failure to heed this warning can lead to seriouspersonal injury such as when an ill-fitting wrenchslips, and you slam your hand into the workbenchor a part of the vehicle.

DISASSEMBLIG THE COMPONENTS

- Before disconnecting any pipe, cable, etc., mark eachpart with a number or distinguishing mark.Each disconnected part must be marked clearly inorder that it may be reassembled in the same positionas it was before disassembly.

- Clean and carefully wash all disassembled parts withfireproof solvent or a nonflammable detergent.

- Keep maiting parts together, since they have worn induring normal use. There are some sets of parts,such as front sprocket, chain, and rear wheelsprocket, which all must be replaced as a set.

- Be careful not to place plastic or painted parts closeto heat sources, where they might be damaged.

REASSEMBLING THE COMPONENTS

Never use a circlip twice. When a circlip is removed,it must be replaced with a new one.When assembling a new circlip be careful not tostretch its ands more than strictly necessary toplace it on the shaft.After installing a circlip, make sure that it iscompletely and firmly inserted in its seat.

Do not use compressed air to clean the bearings.

NOTE The bearings must rotate freely, without haltingor noise otherwise they must be replaced.

- Use only aprilia SPARE PARTS.- Use the recommended lubricants.- Always lubricate parts before reassembly.- When tightening screws, nuts, and bolts, start with

the largest diameter fasteners.When several fasteners are arranged in a pattern,start with the innermost fasteners, and tightendiagonally across the pattern.

WARNING

CAUTION


Release 00 / 2001 - 05

Tighten each fastener successively before applyingthe final tightening torque.

- Always replace gaskets, grommets, circlips, O-ringsand split pins (cotter pins) with new ones.Before assembling, clean all mating surfacescarefully, removing all traces of the old gasket andgasket sealing compound.Also carefully clean any oil seal you plan to reuse.It is recommended that all oil seals be replaced eachtime they are disassembled.Gaskets should never be reused.Apply a thin film of lithium based grease to all oilseals before assembling.Install oil seals and bearings with the identificationmark or serial number facing outward (visible).Copiously lubricate bearings before installation andbefore assembly.

- Make sure that each component has beenreassembled correctly.

- After any repair or periodic maintenance operationis carried out, the vehicle must be test ridden in anarea away from traffic and other hazards.

ELECTRICAL CONNECTORS

The electrical connectors must be disconnected asfollows. Faiture to follow these procedures willirreparably damage the connector and wiring.• Press in the click tab.

Do not pull the cables to disconnect the twoconnectors.• Grasp the two connectors and disconnect them by

pulling in opposite directions.• If dirt, rust, dust or moisture is seen on the connector,

blow out the connector with air.• Make sure that the cables are correctly crimped to

the terminals placed inside the connectors.

NOTE The two halves of the connector fit togetherproperly in only one orientation. Ensure that theconnector is properly aligned before attempting toassmble it.

• Press the connectors firmly together, listening for thetypical “click” sound for those connectors providedwith a click tab. Ensure that both halves of theconnectors are firmly pressed together.

TIGHTENING TORQUES

Remember that the tightening torque of allfasteners on the wheels, brakes, axles, and othercomponents of the suspension system is veryimportant to ensure the safety of the vehicle, andmust be kept at the prescribed values.Check the tightening torque of the fasteners

CAUTION

WARNING

regularly, and always use a torque wrenchreinstalling them.Failure to comply with this warning could allowone of these components to be lost which couldlock a wheel or cause other handling problems withconsequent overturning and risk of serious injuryor even death.

The table below shows tightening torques for screwsand bolts with metric ISO threads, as is used in thisvehicle. These are general values to be used if nospecific value is given in this manual or other apriliaservice literature.

M 6

M 8

M 10

M 12

M 14

M 16

10

12

14

17

19

22

Screw orbolt thread

Tightening torqueWrench

ftlb

4.34

10.84

21.70

39.79

61.49

94.03

6

15

30

55

85

130

(Nm)

If not otherwise indicated, the tightening torques shownshould be used for clean and dry threads, at roomtemperature.NOTE To avoid damage to the threads, tightenscrews and bolts as follows:

• Run up the fasteners finger tight.• Applying half the prescribed tightening torque, tighten

the fasteners that are diametrically opposite eachother.

• Repeat, applying the prescribed tightening torque.

NOTE In this way the pressure exerted by thefastening elements will be uniformly distributed on thejoint surface.

01 / 04Chapter.1


Release 00 / 2001 - 05

SPECIFIC SAFETY RULESFUEL

Gasoline is extremely flammable and in someconditions can become explosive.Therefore, it is necessary to refuel and carry outmaintenance operations involving the fuel systemin a well-ventilated area with the engine off.Do not refuel or do any maintenance on the fuelsystem with the engine running.Do not smoke while refueling or near fuel vapors.Never allow any portion of the fuel system to comein contact with open flames, sparks or other heatsources.

Be careful to avoid spilling fuel when you arerefueling. Spilleng fuel could ignite when itcontacts hot engine or exhaust system surfaces.

If you accidentally spill some fuel, make sure thatit is wiped up or completely evaporated beforestarting the vehicle.

Since gasoline expands in the fuel tank when thevehicle is sitting in the open sun, never fill the tankcompletely to the brim.Leave at least one inch of expansion space.

Avoid any contact of the fuel with your skin, andavoid inhalation of fuel vapors.

Do not ever attempt to siphon fuel from onecontainer to another using your mouth as suctionfor a siphon hose.

Gasoline is poisonous and carcinogenic andcontains chemical substances that cause birthdefects and other reproductive problems.If gasoline shoul be accidentally split on the skinor clothes, immediately wash it off with soap andwater and change clothes.

Should you accidentally spill gasoline in your eyes,flush with a large quantity of water and immediatelycontact a health professional.

Should you accidentally get gasoline into yourmouth, do not induce vomiting.

Drink a large quantity of milk or clear water andimmediately contact a health professional.

Never try to siphon gasoline by sucking it with yourmouth.

Use a manual pump or a similar system.

If your vehicle overturns, it will leak gasoline which

WARNING

is extremely flammable.

Flames or sparks may ignite this which will notonly destroy the vehicle but also could do seriousproperty damage to surrounding property and cau-se serious injuries or even death.

ALWAYS KEEP GASOLINE AWAY FROMCHILDREN.

DISPOSE OF UNWANTED GASOLINE PROPERLY,DO NOT DUMP IT INTO STORM SEWERS OR INTOA SINK OR TOILET.

Before opening the fuel filler cap, if necessry, cleanthe it cap and the part around it with a clean cloth.Prevent any foreign material from getting into thefuel tank, this could lead to serious engine damage.

If you use any container or funnel for refueling,make sure that it is perfectly clean.Any foreign matter getting into the fuel tank maylead to severe damage.

Do not add any additives or other substances tothe gasoline.After refueling, replace the fuel filler cap in thecorrect position and make sure that it is properlyclosed.

Use only unleaded gasoline minimum octane rating(M+R)/2 method 90.

LUBRIFICANTS

Proper vehicle lubrication is critical to safeoperation.Failure to maintain proper lubricant levels or to usethe proper type of clean, new lubricant, can lead toan engine or transmission seizure with subsequentaccident, serious injury or death.

Use latex gloves for the maintenace operations thatrequire contact with used oil.Used oil may cause skin cancer if repeatedly leftin contact with the skin for prolonged periods.Although this is unlikely unless you handle usedoil on a daily basis, it is advisable to thoroughlywash your hans with soap and water after handlingused oil.

KEEP OIL AWAY FROM CHILDREN.

DISPOSE OF OIL PROPERLY.

CAUTION

WARNING

WARNING

01 / 05Chapter.1


Release 00 / 2001 - 05

Be very careful when putting oil in your vehiclenot to spill oil.Clean up any oil spilled immediately bacause oilcan damage the finish of your vehicle.Also, oil on the tires creates an extremely slipperyand therefore dangerous situation.

In case of lubricant leakage do not ride the vehicle,but check to determine the cause of the leakageand repair it.

ENGINE OIL

If the engine oil pressure warning light LED remainson (when the engine is running), or if it comes onduring the normal running of the engine, this meansthat the oil system is not developing sufficientpressure.

Failure to head this warning can lead to engineseizure, upset, and serious injury or even death.

Perform these maintenance operations at one-halfof the specified intervals, if the vehicle is often usedin rainy or very dusty conditions, or on unpavedroads.

BRAKESNOTE This vehicle is equipped with front and rear discbrakes with separate hydraulic systems.

The following information may refer to just one brakingsystem but should be observed whith regard to bothbrakes.

Do not ride the vehicle with worn or malfunctioningbrakes! The brakes are the most important safetysystem of the vehicle, and using the bike withbrakes that are anything less than perfect is verylikely to lead to a collision or upset, withconsequent risk of serious injury or death.

Wet conditions seriously degrade the performan-ce of your brakes.

When the road is wet from rain, you should planto use double the normal stopping distances sinceboth the brakes themselves and the traction of thetires on the road are reduced by the presence ofwater.Water on the brakes from washing your vehicle, orsplashed up from wet roads, or crossing puddles

CAUTION

WARNING

CAUTION

WARNING

or ditches, can wet the brakes sufficiently to greatlyreduce their effectiveness.Failure to heed these warnings may lead to aserious accident with consequent risk of seriousinjury or even death.

The brakes are extremely important for your safety.Do not use the vehicle if the they are neither dirtynor oily, especially after maintenance operationsor inspections.

Check the brake line, make sure that it is not twistedor kinked, nor leaking.

KEEP AWAY FROM CHILDREN.

DISC BRAKES

The brakes are the most important safety systemon your vehicle.For your safety, they must be in perfect repair, sothey should be checked every time you ride thevehicle.

Oil or other fluid on a disc will contaminate thebrake pads.

Dirty pads must be discarted and replaced, a dirtyor oily disc must be cleanned with a high qualitydegreaser.

Check the levels of the brake fluid in the reservoisat the reguired intervals.

Flush the system and renew all of the brake fluidonce every two years.

When the pads wear out the brake fluid level in thereservoir decreases to automatically compensate fortheir wear.The front brake fluid reservoir is located on the rightend of the handlebar near the front brake lever.The rear brake fluid reservoir is under the fairing onthe right side of the vehicle.

Never use the vehicle if any portion of either brakesystem is leaking.

DIPOSE OF USED BRAKE FLUID PROPERLY.

KEEP AWAY FROM CHILDREN.

When using the fluid, take care not to spill it onthe plastic and painted parts, since it damagesthem.

WARNING

WARNING

WARNING

01 / 06Chapter.1


Release 00 / 2001 - 05

To avoid serious damage to the system, do not usefluids other than the recommended ones nor mixdifferent fluids for topping up.Do not use brake fluid taken from old or aireadyopened containers.

Do not use the vehicle if the coolant is below theminimum prescribed level.

Coolant is poisonous! Do not ingest coolant underany circumstance.Should you get coolant in your mouth, rinse withcool water and immediately seek medical attention.Coolant is also very dangerous to your skin andeyes.Should you accidentally get coolant on yourclothing or skin, change clothers immediately.Wash coolant from your skin with hot water andsoap.Should you get coolant in your eyes, flush withplenty of cool water and seek professional medicalhelp at once.Should someone swallow coolant accidentally, in-duce vomiting, rinse mouth with water, andimmediately seek professional medical attention.

DISPOSE OF THE COOLANT PROPERLY.

BE SURE TO KEEP THE DRAINED COOLANT AWAYFROM CHILDREN AND PETS.IT IS SWEET TASTING, AS WELL AS EXTREMELYPOISONOUS, AND IS VERY ATTRACTIVE TOCHILDREN AND PATS.

Use extra caution not to spill the coolant on anyhot parts of the engine. It is flammable, and canemit invisible, noxious fumes.

Always wear rubber or latex gloves when servicingthe cooling system.

The coolant is made up of 50% water and 50%antifreeze.This mixture is ideal for most running temperaturesand ensures good protectin against corrosion.It is advisable to keep the same mixture also in the hotseason, since in this way losses due to evaporationare reduced and it is not necessary to top up veryfrequently.The mineral salt deposits left in the radiator byevaporated water are thus reduced and the efficiencyof the cooling system remains unchanged.If the outdoor temperature is below 0°C, check thecooling circuit frequently and if necessary increase theantifreeze concentration (up to maximum 60%).

CAUTION

CAUTION

WARNING

Use only distilled water when topping off thecooling system. This will reduce damage to theengine.

The coolant is very hot.

Do not remove the filler cap when the engine ishot sice the coolant is under pressure and it willsplash out violently.

If it gets in contact with the skin or with yourclothing, it may cause severe burns.

Be aware of the risk of burns from the coolant.Check the coolant level and top up the expansiontank only after the engine thoroughly cooled.

Do not use your finges or any other object to checkif there is enough coolant.

On the basis of the desired freezing temeperature ofthe coolant mixture, add to the water the percentageof coolant indicated in the following table:

CAUTION

WARNING

WARNING

-20°

-30°

-40°

Freezing point°C

Coolantof the volume

35

45

55

NOTE The characteristics of the various antifreezeliquids are different.

Be sure to read the label on the product to learn thedegree of protection it guarantees.

Use only antifreeze and anticorrosive without ni-trite in order to ensure protection at last -35°C.

TIRES

If the tire is inflated to too high a pressure, anuncomfrontably harsh ride will result, and ridingcomfort will be compromised.Also, road holding, especially during turns and inwet conditions, will likewise be compromised.

If the tire is underinflated (pressure is too low), thetire may slip on the rim with consequent loss ofcontol.

CAUTION

WARNING

01 / 07Chapter.1


Release 00 / 2001 - 05

Again, road holding and handling characteristicswill be degraded, and brake performance will bereduced.

Insure that all tires are equipped with properlyinstalled valve caps.

Changing, repairing, maintenance and balancingoperations are very important and should be carriedout by qualified technicians with any kind of rubberdressing.

Particulary avoid contact to the tire with anygasoline fluid as this will cause rapid deteriorationof the rubber.

If a tire becomes contaminated with oil or gasoline,you cannot clean it .

The tire must be replaced.

Some of the original equipment tires for this vehicleare 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 thevehicle, do not attempt to continue riding.Avoid abrupt braking and steering inputs, and avoidshutting the throttle quickly.

Slowly decrease the throttle setting, moving to theside of the road, using the engine compression toslow you to a stop.

Non-compliance with these instructions may cau-se accidents with consequent risk of injuries oreven death.

Do not install tires with an inner tube on rims fortubeless tires, and viceversa.

WARNING

01 / 08Chapter.1


Release 00 / 2001 - 05

TECHNICAL DATA

02 / 01Chapter.2

TypeEngine typeNumber of valvesNumber of cylindersPiston displacementBore/StrokeCorrected compression ratioIdle rpmStarter systemClutchGearboxLubrication systemCooling system

VariatorPrimaryGears

Secondary

Transmission oil

TypeDiffuser

Fuel injectorAir injector

Type of ignitionPre-ignition

StandardSpark plug gap

BatteryFusesGenerator (magneto)

water/injectionLiquid cooled with direct fuel injection

-single cylinder, horizontal

49,38 cm3

41,0 mm / 37,4 mmr

c = 12,3 ± 0,5

1500 ± 50 r/minelectric

centrifugalautomatic stepless centrifugal clutch

Electric oil pumpLiquid

automatic steplessV- belt

minimum for stepless change: 2.9maximum for stepless change: 0.75

with gears

130 cm3

BINGØ18 mm

SIEMENS DEKASYNERJECT

T.C.I.Variable: 20° at 3000 rpm 17° at 7500 rpm.

NGK R CPR8-E0,8 - 0,9 mm

12 V - 4 Ah7,5 A - 15 A

12 V - 140 W

IGNITION UNIT

ENGINE

CAPACITY

THROTTLE BODY

SPARK PLUG

ELECTRICAL SYSTEM

TRANSMISSION

FUEL FEED


Release 00 / 2001 - 05

Application

Pick-up locking M5 x 12Stator locking M5 x 25Transmission steel plate locking M6 x 12Throttle body (with roller) hose clamp lockingSuction manifold (built-in, hexagonal) locking M6 x 20Suction manifold locking, tear-away screwsTransmission cover M6 x 25Centrifugal clutch cover M6 x 25Bendix support locking M6 x 30Starter motor M6 x 25L/r crankcase locking M6 x 55

M6 x 75 M6 x 100

Wheel bearing retaining plate locking M6 x 16Oil load plug (flanged) M8 x 12Oil unload (Ch. 8) M6 x 12Centrifugal clutch sliding pulley cover locking M4 x 8Head locking (nut) M6 h=9Clutch locking (nut) M10x1,5Flywheel locking (nut) M10x1,25Exhaust studCylinder studSpark plug (thread) M10x1,0Water outlet unit locking M6 x 20Flywheel cover locking M6 x 25Pump cover locking H

2O M6 x 25

Breather on water outlet unit (Ch. 8) M6 x 8Water unload (Ch. 8) M6 x 8Impeller locking M6 x 13Joint entrainment screws (special) M6 x 8,5Compressor screw locking M5 x 20Fuel rail screw locking M5 x 20Centrifugal clutch fixed pulley locking (nut) M12x1,25Temperature sensor

Kgm

0,4 - 0,60,4 - 0,60,8 - 1,2end stop0,8 - 1,20,9 - 1,10,8 - 1,20,8 - 1,20,8 - 1,20,8 - 1,20,8 - 1,2

0,6 - 1,01,0 - 1,40,5 - 0,6

0,20,9 - 1,14,5 - 5,53,5 - 4,50,4 - 0,50,4 - 0,5 1,3 - 1,50,8 - 1,20,8 - 1,20,8 - 1,20,8 - 0,90,8 - 0,90,8 - 0,90,8 - 1,20,4 - 0,50,4 - 0,53,5 - 4,52,0 - 2,2

Sealant

nono

Loctite 270nononononononono

Loctite 243nononononono

Loctite 270no/

nononononononononono

Loctite 572

TIGHTENINGTORQUE

02/ 02Chapter.2

TIGHTENING TORQUE 50 cc WATER COOLED INJECTION ENGINE

Nm

4 - 64 - 68 - 12

end stop8 - 129 - 118 - 128 - 128 - 128 - 128 - 12

6 - 1010 - 145 - 6

29 - 11

45 - 5535 - 454 - 54 - 5

13 - 158 - 128 - 128 - 128 - 98 - 98 - 98 - 124 - 54 - 5

35 - 4520 - 22

Screw


Release 00 / 2001 - 05 02 / 03Chapter.2

CYLINDER + PISTON + RINGS

Standard: mm (in)

0.035-0.045(0.0014-0.0018)

40.970-40.985(1.6130-1.6136)

Measure at 23 (0.9) fromthe skirt end

41.010-41.025(1.6146-1.6152)

Measure at 20 (0.8) fromthe top surface

-

-

Limit: mm(in)

Watere.i.

Watere.i.

Watere.i.

0.120(0.0047)

40.890 min.(1.6098)

41.105(1.6183)

0.05(0.002)

0.05(0.002)

TECHNICAL DATA

Item:

Clearance betweenpiston and cylinder

Piston diam.

Cylinder bore

Cylinder distortion

Cylinder head distortion


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

CYLINDER + PISTON + RINGS

Item:

Piston ring gap, ring free

Piston ring gap, ring assembled intocylinder

Piston ring side clearance

Piston pin bore in piston

Piston pin outside diameter

Limit:mm (in)

1°-2°

1°-2° T

4.5

(0.18)Water

e.i.

Watere.i.

Watere.i.

Watere.i.

Watere.i.

0.08 - 0.18

(0.0031 - 0.0071)

0.01 - 0.05

(0.0004 - 0.0020)

12.002 - 12.010

(0.4725 - 0.4728)

11.996 - 12.000

(0.4723 - 0.4724)

3.6

(0.14)

0.80

(0.031)

-

-

12.030

(0.4736)

11.980

(0.4717)

Standard: mm (in)

T Approx.

1°-2°


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

CONROD + CRANK SHAFT

Item:

Connecting rod small end diameter

Width from crank arm to arm (A)

Misalignment limit (C)

Fly wheel to fly wheel width (D)

Standard crank width

Limit:mm (in)

Watere.i.

Watere.i.

Watere.i.

16.003 - 16.011

(0.6300 - 0.6304) 36.0 ± 0.05

16.040

(0.6315)

-

-

Standard:mm (in)

0.03(0.001)

-

Measured between two opposite points

37.95 - 38.10(1.494 - 1.5)

0.15 - 0.75(0.0059 - 0.029)


Release 00 / 2001 - 05

Item: Limit:mm (in)110.00 - 110.15(4.331 - 4.337)

3.0(0.12)

3500 ± 200 r/min.

7000 ± 300 r/min.

Standard: mm (in)

CLUTCH

Clutch wheel inner diameter

Clutch shoe thickness

Clutch engagement

Clutch lock-up

110.50(4.350)

2.0(0.08)

-

-

THERMOSTAT

Item:

Starts to open at 70° C ± 2° C

Standard:

Thermostat

OIL PUMP

Item:

Inner coil Ri = 26,3 ± 2,6 W a 20° C

Specification:

02 / 06Chapter.2

-

TRANSMISSION

Item:

Reduction ratio

Final reduction ratio

Drive belt width

Free lenght spring pulley

Limit: mm (in)

-

-

17.4(0.685)

104.5(4.114)

Watere.i.

Standard: mm (in)

Variable 2.9 – 0.75

51/15 x 67 x 14

18.4 (0.724)

110 (4.33)Water

e.i.

Limit:mm (in)


Release 00 / 2001 - 05

LUBRICANT TABLE

Transmission oil (recommended): F.C.,SAE 75W - 90 or GEAR SYNTH, SAE75W - 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 30Or other major brand grease for ball bearings with a temperature range of -30 °Cto +140 °C, drop point 150 °C + 230 °C, with good anti-corrosion properties, resistance towater, and oxidation resistance.

03 / 01Chapter.3

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

SPECIAL ENGINE TOOLS

Illustration Tool code Name/function or use

Engine support.

Tool for fitting the teflon ring onto the air injector.

Tool for fitting the teflon ring onto the air injector.

Air injector extractor.

8140229

8140429

8140430

8140431

04 / 01Chapter.4

US


Release 00 / 2001 - 05


Adapter plate for flywheel and crank shaft extraction.

Bearing assembly puller

Reduction gear for crank shaft puller.

Spacer for crank shaft centering.

8140228

8140227

8140225

8140226

04 / 02Chapter.4

Illustration Tool code Name/function or useUS


Release 00 / 2001 - 05


Fuel-oil-air pressure gauge.8140488

04 / 03Chapter.4

Illustration Tool code Name/function or useUS


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

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).

REED VALVE

A

B

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).

1

2


Release 00 / 2001 - 05

TECHNICAL OBSERVATIONS

05 / 01Chapter.5

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. Applyingreverse 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 tomiss after idling for just a short time. In order to rectify this problem, after carrying out all newvehicle receiving operations, start up the engine and ride the scooter for a few kilometers athigh RPM to remove any excess oil left in the cylinder by the production process. This willeliminate spark plug fouling.

Solution:

After carrying out all specified goods-in operations, start up the engine and ride the scooter fora few km, at high revs, to remove any excess oil used for production purposes. This will clearup any spark plug fouling.


Release 00 / 2001 - 05 06 / 01

INJECTION TROUBLESHOOTING

VISUAL ALARMS FOR INJECTION SYSTEM

1 (Max) Flashing 2 Stays on 3 Stays off

PRIORITY BULB ACTION

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 “O N” 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 thethrottle 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 flashesshows the fault. For example, if the led flashes 10 times, it means there is a problem withthe 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 12times: 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 12flashes 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 isrepeated 4 times, after which time the CDI cancels the fault memory. In our example wehave the following sequence: [10 – 12] – [10 – 12] – [10 – 12] – [10 – 12] then cancel.

Chapter.6

spia di controllo iniezione


Release 00 / 2001 - 05

ItalianoEnglishFrançaisDeutschEspañol

06 / 02

DITECH INTERFACEINSTRUCTIONS

Connecting the DITECH interface cartridgeto the scooter:

1 Fit the interface cartridge into theGAMEBOY COLOR.

2 Remove the handlebar plate (see fig. 1)

3 Connect the interface cartridge to the 3-way socket under the handlebar plate,using a suitable adapter

Use of the DITECH interface cartridgeThe software for the DITECH interfacecartridge is structured so that all functionscan be selected easily.Switch on the Gameboy with the ON/OFFswitch (see Fig).To scroll the menu, use the UP and DOWNkeys on the cross-shaped pushbutton.Press A to confirm and B to return to theprevious menu.The following functions can be selected:

Language Selection:A list of languages

Engine parameters:The following parameters are displayed:engine rpm, Battery voltage and engine tem-perature (in º C).


Engine parameters:Engine rpm: 890Battery voltage: 12.50 VEngine temp. 78° C.

Injection parameters:The engine parameters displayed on thescreen refer to: engine rpm, percentage ofthrottle opening (0 – 100%), ignition advance(in degrees) and engine condition. Enginecondition is given with the following words:off, starting, on, ticking over or cut-off.

Injection parameters:Engine rpm: 9150Throttle valve 74%Pre-ignition 6° C.

Engine condition: on

Engine history:This displays the number of hours the enginehas been in operation.

Engine history:Hours in operation: 15.08 h

Chapter.6


Release 00 / 2001 - 05 06 / 03


Fig. 1

CROSS-SHAPEDPUSHBUTTON

SWITCHON/OFF

KEY ”A”

KEY ”B”

Chapter.6


Release 00 / 2001 - 05

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)

06 / 04


Chapter.6

Pressure gauge (supplied with kit 8140175).

Cod. 8140181

aprilia part #8140581 - 05/01 - USAPro

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Documents

Ditech Water Cooled Part1