Aprilia RS50 1999-2010 Workshop Repair Service Manual

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🏷️ Basic Information Identification Make: Aprilia Model: RS50 Model Generation: First Generation Codes Chassis Code: AM50 👋 Introduction Market Position Segment: Lightweight Sportbike / Superbike Replica Target Audience: Entry-level riders,...

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Taper: Motorcycle

Distributeur:

UGS: 602490

Mots clés: 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 Aprilia Featured Motorcycle Motorcycles RS Models RS50

Variantes de produits

Description

🏷️ Basic Information

Identification

Make:

Aprilia

Model:

Model Generation:

First Generation

Codes

Chassis Code:

👋 Introduction

Market Position

Segment:

Lightweight Sportbike / Superbike Replica

Target Audience:

Entry-level riders, performance-oriented youth, track day enthusiasts.

Competitive Analysis

Key Competitors:

Yamaha TZR50, Aprilia RS Tuono 50, Gilera SMT 50, Derbi Senda R 50, Honda NSR50.

Key Features

Design Philosophy:

Mimics the larger Aprilia RS series sportbikes, offering premium styling and components in a 50cc package.

Performance Focus:

Emphasizes sporty handling, responsive engine performance for its class, and aggressive aesthetics.

Customization Potential:

Popular platform for tuning and modification due to its performance-oriented 2-stroke engine.

📋 Manual Details

Coverage Areas

Manual Type:

Workshop Repair Service Manual

Language:

English

Format:

Digital (PDF)

Page Count

Estimated Page Count:

📖 Manual Coverage

Systems Covered

Engine Overhaul:

Complete teardown, inspection, and reassembly of the 2-stroke engine.

Cooling System:

Maintenance and repair of the liquid cooling system, including radiator, pump, and thermostat.

Fuel System:

Carburetor (Dell'Orto PHVA 12/17.5) tuning, cleaning, and overhaul; fuel tank, lines, and pump.

Ignition System:

Ignition coil, CDI unit, spark plug, wiring, and timing.

Exhaust System:

Inspection and maintenance of the exhaust pipe and muffler.

Transmission:

6-speed gearbox, clutch (hydraulic), shift mechanism, and gear ratios.

Drivetrain:

Chain drive, sprockets, and final drive maintenance.

Suspension:

Front (upside-down forks, Marzocchi or Paioli) and rear (monoshock, Sachs or similar) fork and shock absorber servicing.

Brakes:

Front and rear disc brake systems, hydraulic lines, master cylinders, calipers, and pads.

Electrical System:

Wiring diagrams, battery, lighting, starting system, and instrument panel.

Frame And Bodywork:

Chassis inspection, fairings, seat, fuel tank, and body panel removal/installation.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, chain adjustment, spark plug service.

Troubleshooting:

Diagnostic procedures for common starting, running, and electrical issues.

Engine Rebuild:

Detailed steps for piston, cylinder, crankshaft, and bearing replacement.

Carburetor Rebuild:

Jetting adjustments, float bowl service, and diaphragm replacement.

Suspension Servicing:

Fork oil changes, seal replacement, and rear shock adjustments.

Brake Bleeding:

Procedure for bleeding hydraulic brake systems.

Electrical Component Testing:

Testing of ignition components, stator, and lighting.

Bodywork Repair:

Fairing repair and replacement instructions.

Technical Depth

Depth Level:

Comprehensive (from basic maintenance to complete engine rebuild).

Diagnostic Charts:

Includes detailed troubleshooting flowcharts.

Torque Specifications:

All critical fastener torque values provided.

Wiring Diagrams:

Clear and detailed electrical system schematics.

Illustrations And Diagrams:

Numerous step-by-step illustrations and exploded views.

📊 Manual Specifications

File Format

Digital Format:

Searchability:

Fully searchable text for quick information retrieval.

Print Quality:

High-resolution scans for clear printing.

Print Quality

Image Clarity:

Sharp and clear technical illustrations and photographs.

Binding Type

Binding:

N/A (Digital PDF)

Paper Type

Paper Quality:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Liquid-cooled, 2-stroke, single-cylinder

Bore X Stroke:

39.5 mm x 40.5 mm (typical for AM6 engine)

Displacement:

49.7 cc

Compression Ratio:

8.3:1 to 8.5:1 (approximate)

Valvetrain:

Reed valve induction

Performance

Horsepower:

Approx. 7.5 HP @ 9000 RPM (stock, may vary by region/de-restriction)

Torque:

Approx. 5.5 Nm @ 8500 RPM (stock)

Fuel System

Carburetor:

Dell'Orto PHVA 12 or 17.5mm

Fuel Type:

Unleaded gasoline (RON 95 or higher recommended)

Fuel Mixture:

Automatic oil injection system for 2-stroke oil

Cooling System

Cooling Method:

Liquid-cooled

Lubrication

Engine Oil Type:

API TC or JASO FD certified 2-stroke synthetic oil

Transmission Oil Type:

SAE 10W-30 API GL-3 or GL-4 transmission oil

🔧 Transmission

Standard

Transmission Type:

6-speed manual

Clutch Type:

Wet multi-plate, hydraulically operated

Features

Gear Ratios:

Detailed ratios for each of the 6 gears provided in manual.

Final Drive:

Chain drive, 13/52 (example ratio, subject to change)

📐 Dimensions

Exterior

Length:

Approx. 1950 mm

Width:

Approx. 720 mm

Height:

Approx. 1130 mm

Wheelbase:

Approx. 1330 mm

Weights

Dry Weight:

Approx. 103 kg

Fuel Tank Capacity:

Approx. 13 liters

Oil Tank Capacity:

Approx. 1.5 liters

Wheels And Tires

Front Tire Size:

110/70-17

Rear Tire Size:

130/70-17

Front Wheel:

17 inch alloy

Rear Wheel:

17 inch alloy

Dimensions

Seat Height:

Approx. 820 mm

🛡️ Safety Features

Ratings

Safety Ratings:

N/A (Lightweight Motorcycle Class - typically not subjected to formal crash testing like cars)

Active Features

Braking System:

Hydraulic disc brakes front and rear for effective stopping power.

Suspension Stability:

Upside-down front forks and adjustable rear monoshock contribute to stable handling.

Passive Features

Lighting:

Halogen headlight, tail light, and turn signals for visibility.

Frame Construction:

Steel twin-spar frame for rigidity and rider feedback.

💡 Technology Features

Infotainment

Instrument Panel:

Analog speedometer, tachometer, odometer, trip meter, and warning lights.

Driver Assistance

ABS was not a standard or commonly available option on the RS50 during this period.

Connectivity

Connectivity Features:

N/A (Basic motorcycle electronics)

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000-5,000 km or annually (transmission oil).

Spark Plug Replacement:

Every 5,000-8,000 km, or as needed based on inspection.

Air Filter Cleaning:

Every 2,000-3,000 km or more frequently in dusty conditions.

Chain Lubrication Adjustment:

Lubricate every 500 km, adjust chain slack as needed.

Coolant Flush:

Every 2 years or 24,000 km.

Fluid Specifications

Engine Oil Capacity:

N/A (2-stroke oil is mixed automatically)

Transmission Oil Capacity:

Approx. 0.8 - 1.0 liters (refer to manual for exact amount)

Coolant Type:

Ethylene glycol-based antifreeze/coolant, mixed 50/50 with distilled water.

Brake Fluid Type:

DOT 4 hydraulic brake fluid.

Known Issues

Carburetor Fouling:

Can occur with incorrect jetting or poor quality fuel/oil mixture, leading to rough running.

Power Valve Sticking:

Carbon buildup can cause the exhaust power valve to stick, affecting performance.

Electrical Gremlins:

Aging wiring or poor connections can sometimes lead to intermittent electrical faults.

Suspension Seals:

Front fork seals can degrade over time, leading to oil leaks.

Clutch Wear:

Clutch plates may require replacement after extensive use, especially in aggressive riding.

📚 Vehicle History

Brand Heritage

Aprilia Legacy:

Aprilia is an Italian manufacturer with a strong heritage in racing and high-performance motorcycles, particularly in smaller displacement classes.

Model Evolution

Rs50 Introduction:

The RS50 was introduced as a premium, youth-oriented sportbike, designed to offer the look and feel of Aprilia's larger racing machines.

Key Engine Platform:

Primarily utilized the robust and widely used Minarelli AM6 2-stroke engine, known for its tunability.

Production

Production Period:

1999-2010

Manufacturing Location:

Italy

🏆 Awards & Recognition

Recognitions

Awards And Accolades:

While specific awards for the RS50 are rare, it was consistently recognized for its class-leading styling and handling among 50cc sportbikes.

Ratings

User Reviews:

Generally highly rated by owners for its sporty nature, build quality (for its class), and attractive design.

Certifications

Emissions Compliance:

Engine design would have met prevailing emissions standards for its market at the time of sale.