aprilia mx 50

DISASSEMBLY SEQUENCE

REASSEMBLY

For reassembly, reverse the order of operations for dismantling.

27

8

6

28

40

44

41

14

40

39

4847

21

45

26

23

29

30

25

20

21

22

4643

26

24

11

10

47

38

35

37

36

6

7

4

2

1

17

9

42

36

11

31

32

18

15

19

13

12

19

16

34

333

3

5��

BODYWORK

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1) REMOVING SEAT (1)Unscrew and remove the nut (2) located under the seat (1)

2) REMOVING RIGHT-HAND (4) AND LEFT-HAND (5) AIR-SCOOPSUnscrew and remove the two screws (3) securing the air-scoops (4),(5).Unscrew and remove the two screws (6) connecting the air-scoops (4),(5), tothe radiator grille (7).

3) REMOVING RADIATOR GRILLE (7)Unscrew and remove the screw (8) connecting the radiator grille (7) to the frame.Unscrew and remove the two screws (6) connecting the air-scoops (4),(5), tothe radiator grille (7).Remove the radiator grille, (7) pulling it downwards, with the handlebars turnedto one side.

4) REMOVING LEFT-HAND (9) AND RIGHT-HAND (10) SIDEPANELSUnscrew and remove the screw (11) holding the sidepanel (9),(10) to theframe.

5) REMOVING TOOLBOX (12)Unscrew and remove the two screws securing the toolbox (12).

6) REMOVING TAILPIECE (17)Remove the seat (1), following the procedure “REMOVING SEAT”.Unscrew and remove the two bolts (14), being careful of the corresponding nuts(15) on the underside.Unscrew and remove the two screws (16) securing the tailpiece (17).

7) REMOVING NUMBERPLATE BRACKET (18)Remove the seat (1), following the procedure “REMOVING SEAT”.Remove the tailpiece (17), following the procedure “REMOVING TAILPIECE”.Unscrew and remove the three screws (19)Disconnect the rear indicator connectors (Table 4)Disconnect the tail lamp connector block (Table 4) (the connector block is locatedabove the battery).

8) REMOVING HEADLAMP COWLING (20)Unhook the two O-rings (21).Remove the headlamp cowling (20) by pulling it downwards.Disconnect the headlamp connectors (Table 4).

9) REMOVING FRONT FENDER (22)Unscrew and remove the four bolts (23)Remove the front fender (22)

10) REMOVING RIGHT-HAND (24), AND LEFT-HAND (25) FORKSHROUDSUnscrew and remove the two screws (26)In the case of the left-hand fork shroud (25) unscrew and remove thescrew (27), being careful of the corresponding nut on the inside (30),to disengage the front brake hose.In the case of the right-hand fork shroud (24) unscrew and removethe screw (28) being careful of the corresponding nut on the inside(29) to disengage the tachometer cable.

11) REMOVING CHAINGUARD (31)Unscrew and remove the two screws (32)

12) REMOVING FRONT SPROCKET COVER (33)Unscrew and remove the two screws (34).

13) REMOVING SHOCKABSORBER SHROUD (35)Remove the sidepanels, following the procedure “REMOVING LEFT-HAND (9) AND RIGHT-HAND (10) SIDEPANELS”.Unscrew and remove the two screws (36), taking particular note,especially when reassembling, of the earth lead (42) located underthe left-hand screw. Unscrew and remove the screw (37).

14) REMOVING FUEL TANK (38)Remove the seat, following the procedure “REMOVING SEAT (1)”.Remove the right-hand and left-hand air-scoops, following theprocedure “REMOVING RIGHT-HAND (4) AND LEFT-HAND (5) AIR-SCOOPS”.Unscrew and remove the central bolt (39) holding the tank (38) to theframe.Unscrew and remove the two side bolts (40).Turn off the fuel tap (41) located under the fuel tank (38).Disconnect the tank/carburettor fuel hose (Table 5).

15) REMOVING RIGHT-HAND (43), AND LEFT-HAND (44)HANDGUARDS AND RIGHT-HAND (45), AND LEFT-HAND (46)MIRRORSUnscrew and remove the nuts (47) which secure the rear view mirrors(45),(46);Remove the mirrors, followed by the handguards (43),(44).

16) REMOVING HANDLEBARS (48)Remove the rear view mirrors (45),(46) and the handguards (43),(44),following the procedure “REMOVING RIGHT-HAND (43), AND LEFT-HAND (44) HANDGUARDS AND RIGHT-HAND (45), AND LEFT-HAND (46) MIRRORS”.Remove the front brake master cylinder (Table 3).Unscrew and remove the two screws (35) (Table 5), Remove thetwistgrip (34) (Table 5)Unscrew and remove the screw (36) (Table 5); remove the left-handhandlebar switch (37) (Table 5)Remove the handlebar clamps (9) after unscrewing and removingthe four screws (8) (Table 2)

BODYWORK


REASSEMBLY


3638 37 33

32

25

1412

22

28

26

2928

30

3

3

15

18

9

2

1

10

19

23

27

21

17

16

13

118

8

9

34

35 31

24

20

56 4

5

7

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FRONT FORKS - SWINGING ARM

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1) REMOVING FRONT FORK ASSEMBLY (1)Support the motorcycle securely to avoid the risk of personal injury and damageto the motorcycle itself.Unscrew and remove the screws and remove the right-hand and left-hand forkshrouds, following the procedure “REMOVING RIGHT-HAND (24), AND LEFT-HAND (25) FORK SHROUDS” (Table 1)Remove the front brake caliper, following the first part of the procedure“REMOVING FRONT BRAKE SYSTEM (1)” (Table 3).Remove the front wheel spindle and the front wheel, following the procedure“REMOVING FRONT WHEEL (18)” (Table 3).Remove the headlamp cowling, following the procedure “REMOVINGHEADLAMP COWLING (20)” (Table 1).Remove the direction indicator brackets, following the procedure “REMOVINGRIGHT-HAND (16) AND LEFT-HAND (17) DIRECTION INDICATORS” (Table4).Slack off the pinchbolt (3) in the fork top yoke (2).Slack off the pinchbolts (5) in the fork bottom yoke (4).Slide out the right-hand (6), or the left-hand (7), fork leg as necessary.Carry out the last three stages in the procedure first for one fork leg then for theother.

2) REMOVING SHOCKABSORBER (11)Remove the fuel tank, following the procedure “REMOVING FUEL TANK (38)”(Table 1).Remove the right-hand sidepanel, following the procedure “REMOVING LEFT-HAND (9) AND RIGHT-HAND (10) SIDEPANELS” (Table 1).Support the rear end of the motorcycle securely to avoid the risk of personal injuryand damage to the motorcycle itself.Unscrew and remove the bolt (12) holding the shockabsorber (11) to the frame(10), being careful of the corresponding nut (13) and the bush (14).Attention: when reassembling, grease the bush (14).Unscrew and remove the bolt (15) connecting the shockabsorber (11) to thesuspension rocker-arm (18), being careful of the corresponding nut (16) and theneedle-roller bearing (17).Attention: when reassembling, grease the needle-roller bearing (17).Remove the shockabsorber (11).

3) REMOVING SUSPENSION ROCKER-ARM (18) AND LINK-ARM(19)Support the rear end of the motorcycle securely to avoid the risk ofpersonal injury and damage to the motorcycle itself.Remove the shockabsorber (11), following the procedure“REMOVING SHOCKABSORBER (10)”.Unscrew and remove the centre bolt (22) of the suspension rocker-arm (18), being careful of the corresponding nut (20) and the needle-roller bearing (21).Attention: when reassembling, grease the needle-roller bearing (21).Unscrew and remove the bolt (24) connecting the suspension link-arm (19) to the frame (10), being careful of the nut (23) and the spacer(25).Attention: when reassembling, grease the spacer (25).Remove the suspension rocker-arm (18) and the link-arm (19) as aunit.

4) REMOVING SWINGING ARM (26)Support the rear end of the motorcycle securely to avoid the risk ofpersonal injury and damage to the motorcycle itself.Slack off the rear wheel spindle (Table 3) so that the wheel can slideforward, creating enough slack in the chain to allow it to be taken offthe front sprocket (Table 3).If it is necessary to remove the rear wheel, follow the procedure“REMOVING REAR WHEEL (24)” (Table 3).Unscrew and remove the centre bolt (22) of the suspension rocker-arm (18), being careful of the corresponding nut (20) and the needle-roller bearing (21).Attention: when reassembling, grease the needle-roller bearing (21).Unscrew and remove the bolt (24) connecting the suspension link-arm (19) to the frame (10), being careful of the nut (23) and the spacer(25).Attention: when reassembling, grease the spacer (25).Unscrew and remove the long pivot bolt (27) connecting the swingingarm (26) to the frame (10), being careful of the spacer (29) and thebushes (28).Attention: when reassembling, grease the bushes (28).Remove the swinging arm (26).

5) REMOVING SIDESTAND (30)Remove the spring assembly (31).Unscrew and remove the nut (32), being careful of the bolt (33).Attention: when reassembling, grease the bolt and apply Loctite 243to the threads of the nut.Remove the sidestand (30).

6) REMOVING RIGHT-HAND (34) AND LEFT-HAND (35) FRONTFOOTRESTSUnscrew and remove the bolt (36), being careful of the correspondingnut (37) and of the spring (38).Remove the front footrest (34) or (35).Repeat the procedure for the other footrest.

FRONT FORKS - SWINGING ARM


REASSEMBLY


4

35

33

4

32

34

15

32

7

2 3

30

17

24

14

16

6

11

9

1

25

23

21

2221

2019

18

8

10

27 2829

31

13

12

2627

28

5

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FRONT/REAR BRAKES - FRONT/REAR WHEEL

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1) REMOVING FRONT BRAKE SYSTEM (1)Disengage the front brake hose (2) from the upper hose guide (3) located onthe indicator bracket (Table 4).Disengage the front brake hose (2) from the guide fitted to the left-hand forkshroud, and remove the shroud itself, following the procedure “REMOVINGRIGHT-HAND (24), AND LEFT-HAND (25) FORK SHROUDS” (Table 1).Unscrew and remove the two bolts (4).Remove the front brake caliper (5).Remove the right-hand handguard, following the procedure “REMOVINGRIGHT-HAND (43), AND LEFT-HAND (44) HANDGUARDS AND RIGHT-HAND (45), AND LEFT-HAND (46) MIRRORS”Disconnect the front stop-switch harness (Table 4).Unscrew and remove the two screws (6) and remove the mounting bracket (7)for the front master-cylinder (8).Remove the complete front brake system (1).

NOTE: please have the sense to keep the master-cylinder higher than the caliperat all times.

2) REMOVING REAR BRAKE SYSTEM (9)Remove the right-hand sidepanel, following the procedure “REMOVING LEFT-HAND (9) AND RIGHT-HAND (10) SIDEPANELS” (Table 1).Remove the clip (10) connecting the rear master-cylinder (11) to the rear brakelever (12).Disconnect the stop-switch harness.Undo the hose-clips on the swinging arm.Unscrew the two screws (13).Remove the rear brake caliper (14).Unscrew and remove the screws (15) holding the rear master-cylinder reservoir(16).Unscrew the bolts (17) securing the rear master-cylinder (11).Remove the complete rear brake system (9).

NOTE: please have the sense to keep the master-cylinder higher than the caliper atall times.

3) REMOVING FRONT WHEEL (18)Remove the right-hand and left-hand fork shroud, following theprocedure “REMOVING RIGHT-HAND (24), AND LEFT-HAND (25)FORK SHROUDS (25)” (Table 1).Unscrew and remove the front wheel spindle (19), paying particularattention to the order in which the following parts are fitted:speedometer drive (20), bearings (21), spacer (22), spacer (23).Attention: Grease when reassembling.Remove the front wheel (18).

4) REMOVING REAR WHEEL (24)Unscrew and remove the rear wheel spindle (25) (Table 3), payingparticular attention to the order in which the following parts are fitted:self-locking nut (26), plain washers (27), chain adjusting plates (28),spacer (29), brake caliper mounting plate (30), spacer (31), bearings(32), spacer (33).Attention: Grease when reassembling.Take the chain (34) off the rear sprocket (35).Attention: Grease when reassembling.Remove the rear wheel (24).

FRONT/REAR BRAKES - FRONT/REAR WHEEL


REASSEMBLY


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ELECTRICAL SYSTEM

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1) REMOVING RIGHT-HAND (1) AND LEFT-HAND REAR DIRECTIONINDICATORSUnscrew and remove screw (3), being careful of the corresponding nut (4).Disconnect the connector (5).If necessary repeat the operation for the other direction indicator.

NOTE: to remove just the indicator lens, unscrew the lens fitting screw. If necessary,replace the bulb after removing the indicator lens.

2) REMOVING TAIL LAMP (10)Unscrew and remove the two nuts (6) located under the numberplate bracket,being careful of the two spacers (7).Disconnect the connector block (8), after removing the seat, following theprocedure “REMOVING SEAT (1)” (Table 1).Remove the tail lamp (10).

NOTE: to remove just the tail lamp lens (11), unscrew and remove the two screws(9). If necessary, replace the bulb after removing the tail lamp lens (11).

3) REMOVING HEADLAMP (12)Remove the headlamp cowling, following the procedure “REMOVING HEADLAMPCOWLING (20)” (Table 1).Unscrew and remove the two screws (13).Unscrew and remove screw (14) (headlamp adjustment screw).Disconnect connector (15).Remove the headlamp (12).

4) REMOVING RIGHT-HAND (16) AND LEFT-HAND (17) DIRECTIONINDICATORSUnscrew and remove screw (18).Disconnect connector (19) or (20) after removing the headlamp cowling, followingthe procedure “REMOVING HEADLAMP COWLING (20)” (Table 1).

NOTE: to remove just the indicator lens, unscrew the lens fitting screw. If necessary,replace the bulb after removing the indicator lens.

5) REMOVING INSTRUMENT PANEL (21)Remove the headlamp cowling, following the procedure “REMOVINGHEADLAMP COWLING (20)” (Table 1).Slack off tachometer cable guide (22) and speedometer cable guide(23).Disconnect connector (24) from the tachometer (26); disconnectconnector (25) from the speedometer (27).Unscrew and remove the two screws (28) connecting the panel to thetop yoke, paying particular attention to the order in which the followingparts are fitted: spacers (29), dampers (30) and nuts (31).To remove just the tachometer cable (26) or the speedometer cable(27), remove the split pins (32).

6) REMOVING BATTERY (33)Remove left-hand sidepanel, following the procedure “REMOVINGLEFT-HAND (9) AND RIGHT-HAND (10) SIDEPANELS” (Table 1).Remove the battery cover (Table 5) after unscrewing and removingthe four fixing screws (Table 5).Attention: one of the four screws has a rubber washer; pay particularattention when reassembling.Remove the battery (33), rotating it clockwise and pulling it downwardsat the same time.Disconnect first the negative (-) cable, then the positive (+) cable fromthe battery (33), in that order.Attention: on reassembly, connect first the positive (+) cable, thenthe negative (-) cable, in that order.

7) REMOVING FLASHER RELAY (34)The flasher relay (34) can be removed from the right-hand side of thevehicle, without having to remove any other part.

8) REMOVING FUSE (45) AND FUSE/DIODE BOX RUBBER (35)The fuse (45) can be reached directly from the right-hand side of thevehicle, without having to remove any other part.

9) REMOVING TRANSDUCER (36) AND VOLTAGE REGULATOR (37)Remove the fuel tank, following the procedure “REMOVING FUELTANK (38)” (Table 1).Unscrew and remove the two screws (38), being careful of the nut(39).Disconnect the leads, having first labelled them to ensure correctrefitting.Remove the transducer (36).Unscrew and remove the screw (40), being careful of the nut (41).Disconnect the leads, having first labelled them to ensure correctrefitting.Remove the voltage regulator (37).

10) REMOVING HORN (42)Disconnect the connectors (44).Unscrew and remove the nut securing the horn (42) to the supportbracket (43).Remove the horn (42).

NOTE: the horn (42) is supplied as a spare part complete with the supportbracket (43). To replace the horn/support bracket assembly,remove the radiator grille, following the procedure “REMOVINGRADIATOR GRILLE (7)” (Table 1).

ELECTRICAL SYSTEM

16

32

2223

27

15

25

28

18

18

19

26

24

42

41

37

31

13 14

13

1712

32

20

54 3

40

38

6

39

35

1

5

3

42

33

21

30

29

29

36

34

4443

45

10

119

8

7

7


REASSEMBLY


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ENGINE AND COMPONENTS

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1) REMOVING AIR FILTER BOX (1)Remove the sidepanels, following the procedure “REMOVING LEFT-HAND(9) AND RIGHT-HAND (10) SIDEPANELS” (Table 1).Remove the battery, following the procedure “REMOVING BATTERY (33)”(Table 4).Remove the flasher relay, following the procedure “REMOVING FLASHERRELAY (34)” (Table 4)Remove the fuse/diode box rubber.Unscrew and remove the screw (4).Slack off the clamp connecting the air filter box to the inlet duct.Remove the air filter box (1).

2) REMOVING TWO-STROKE OIL TANK/EXPANSION BOTTLE (6)Remove the seat, following the procedure “REMOVING SEAT (1)” (Table 1).Remove the right-hand and left-hand air-scoops, following the procedure“REMOVING RIGHT-HAND (4) AND LEFT-HAND (5) AIR-SCOOPS” (Table1).Remove the fuel tank, following the procedure “REMOVING FUEL TANK (38)”(Table 1).Unscrew and remove the two screws (7).

Slack off the clamp (8) and remove the pipe (9) from the radiator cap (10).Disconnect the connectors (11).Remove the two-stroke oil tank/expansion bottle (6).

3) REMOVING RADIATOR (12)Remove the right-hand and left-hand air-scoops, following the procedure“REMOVING RIGHT-HAND (4) AND LEFT-HAND (5) AIR-SCOOPS” (Table 1).Remove the radiator grille, following the procedure “REMOVING RADIATORGRILLE (7)” (Table 1).Drain the coolant from the cooling system by unscrewing the screw with the copperwasher on the water pump cover.Unscrew and remove the screw (13) and the screw (14).Slack off the clamps (15) and (16).Unscrew and remove the radiator cap (10).Remove the radiator (12), lifting it gently.

4) REMOVING SILENCER (17)Unscrew and remove the screw (18), paying particular attention to the order inwhich the following parts are fitted: washers (19), silent-block (20), spacer (21),nut (22).

Slack off the expansion pipe/silencer clamp (23).Remove the silencer (17).

5) REMOVING EXHAUST EXPANSION PIPE (24)Slack off the expansion pipe/silencer clamp (23) and separate theexpansion pipe (24) from the silencer (17).Unhook the springs (25) from the barrel.Unscrew and remove the bolt (26).Remove the expansion pipe (24).

6) REMOVING CARBURETTOR (27)Remove the fuel tank, following the procedure “REMOVING FUELTANK (38)” (Table 1).Disconnect the throttle cable (28) from the carburettor (27).Disconnect the oil feed pipe.Slack off the clamp (5) connecting the carburettor (27) to the inletsleeve.Unscrew the bolt on the inlet manifold to separate the carburettor (27)from the manifold.Remove the carburettor (27).

7) REMOVING ENGINE (29)Remove the seat, following the procedure “REMOVING SEAT (1)”(Table 1).Remove the right-hand and left-hand air-scoops, following theprocedure “REMOVING RIGHT-HAND (4) AND LEFT-HAND (5) AIR-SCOOPS” (Table 1).Remove the fuel tank, following the procedure “REMOVING FUELTANK (38)” (Table 1).Remove the expansion pipe, following the procedure “REMOVINGEXHAUST EXPANSION PIPE (24)”.Drain the coolant from the cooling system by unscrewing the screwwith the copper washer on the water pump cover.Disconnect the cooling hoses from the water pump and the cylinderhead.Unscrew and remove the two oilpump cover screws.Disconnect the oilpump cable.Remove the oilpump.Disconnect the oil feed pipe to the carburettor.Disconnect the tachometer cable (Table 4).Disconnect the clutch cable (30).Separate the engine (29) from the carburettor (27) by unscrewing thebolt on the inlet manifold.Disconnect the inlet manifold heating pipe (31).Pull the sparkplug cap off the sparkplug itself.Disconnect the neutral light lead connector.Disconnect the lead to the CDI unit/coil (Table 4)Disconnect the lead to the voltage regulator (Table 4).Disconnect the engine earth lead.Remove the front sprocket cover, following the procedure“REMOVING FRONT SPROCKET COVER (33)” (Table 1).Slack off the rear wheel spindle (Table 3) so that the wheel can slideforward, creating enough slack in the chain to allow it to be taken offthe front sprocket (Table 3).Remove the front sprocket (32) from the engine (29).Unscrew and remove the three long bolts (33) which hold the enginein the frame.Remove the engine (29) (preferably from the left-hand side).

ENGINE AND COMPONENTS

28

30

37

36

3534

7

31

33

17

15

13

10

12

4

11

6

8 9

14

16

27

33

5

3

1

2

22

23

24

26

3

18

19

20

25

21

1932

29

LEGEND

ASD

1) Generator2) Ignition coil4) Voltage regulator5) Fuses6) Battery8) Rear stoplight switch9) Mixer oil reserve sensor

10) Neutral indicator11) Rear left direction indicator12) Rear light13) Rear right direction indicator14) Blinking15) Ignition switch / steering lock / light switch17) Left dimmer switch

CABLE COLOURS

Ar OrangeAz Light blueB BlueBi WhiteG YellowGr GrayM BrownN BlackR RedV GreenVi Violet

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WIRING DIAGRAM

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18) Complete dashboard19) Dashboard lamps20) Direction indicator warning light21) Low beam warning light21) High beam warning light22) Mixer oil reserve warning light23) Neutral warning light24) Horn25) Front right direction indicator26) Low beam bulb27) Front parking light28) Front left direction indicator29) Multiple connectors30) Spark plug31) Front stoplight switch

WIRING DIAGRAM MX 50

ASD

29

29

18

23 2122 20

19

2627

25

24

29

30

6 9

8 10 29

29

11

12

13

31

29

29

1415

1517

28

4

2

5

B

R

R N

BiRV

VAz

GVi

R / VGr

RMNBiB

VAz

GVi

R / V

B / N

RR

MV / G

G

Az

B

ArBi / R

B

V M Vi V Bi B R Az G B

M Bi Vi R Az G B V

M Bi Vi R Az G B R /

V

Gr

Bi B / N

Az R G N Bi V

Gr

Bi B / N

Az R G N Bi V

B Ar R /

V

R /

VB

/ N

Bi / R

Bi / R

V G

B Ar R /

VV G

B Ar R /

VV G

B Ar R /

V

Bi /

RBi

/ R

V

B Ar R /

VV

G

G

Az

NBiB

R

R / VGr

B

BV

G

FUS.

7,5

A

Bi /

R

R /

VV

/ G

Vi B R /

VV

/ G

M

V B

G

1

5756

ST

31

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aprilia mx 50

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