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Aprilia Rs50 1999-2005 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Aprilia Model: RS50 Model Variant: Sport Production (SP) Generation Generation Code: Original (First Generation) Codes Production Code: Likely varies by specific year and market, often...
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Taper: Motorcycle
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UGS: 602470
Aprilia Rs50 1999-2005 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
RS50
Model Variant:
Sport Production (SP)
Generation
Generation Code:
Original (First Generation)
Codes
Production Code:
Likely varies by specific year and market, often internal Aprilia designations
👋 Introduction
Market Position
Market Position:
The Aprilia RS50 was positioned as a premium, high-performance 50cc sportbike, targeting younger riders and enthusiasts with its race-inspired styling, advanced chassis, and potent two-stroke engine for its class. It aimed to provide a gateway into the world of sportbike riding.
Competitive Analysis
Competitive Analysis:
Competed directly with other European 50cc sportbikes such as the Yamaha TZR50, MBK X-Power, Derbi GPR50, and Honda NSR50. The RS50 was often lauded for its superior handling, braking, and authentic supersport aesthetics compared to many competitors.
Key Features
Key Features:
Aggressive styling mirroring larger Aprilia RSV Mille/Falco models, advanced aluminum twin-spar frame, high-performance liquid-cooled 2-stroke engine (often Rotax 140 or similar), capable suspension, powerful disc brakes, and a lightweight chassis.
📋 Manual Details
Coverage Areas
Coverage Areas:
Full workshop and service repair coverage for Aprilia RS50 models
Page Count
Page Count:
Estimated 300+ pages (typical for comprehensive workshop manuals of this era)
Manual Type
Manual Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
Digital (likely PDF)
📖 Manual Coverage
Systems Covered
Systems Covered:
Engine, Fuel System, Ignition System, Cooling System, Exhaust System, Transmission, Clutch, Drive Train, Suspension (Front & Rear), Braking System (Front & Rear), Wheels & Tires, Electrical System, Chassis, Frame, Bodywork, Controls, Tools & Equipment
Procedures Included
Procedures Included:
Routine Maintenance, Scheduled Servicing, Troubleshooting, Diagnostics, Component Removal & Installation, Engine Rebuilding, Carburetor Tuning, Electrical System Repair, Brake Bleeding & Servicing, Suspension Adjustment & Overhaul, Frame Inspection & Repair, Bodywork Repair & Adjustment, Torque Specifications, Wiring Diagrams, Special Tools Usage
Technical Depth
Technical Depth:
Comprehensive. Covers everything from basic checks and fluid changes to full engine teardown and rebuild, electrical diagnostics, and chassis repairs. Suitable for experienced DIY mechanics and professional technicians.
📊 Manual Specifications
File Format
File Format:
PDF (Portable Document Format)
Print Quality
Print Quality:
High-resolution scans of original factory documentation, ensuring clarity of text, diagrams, and images.
Binding Type
Binding Type:
N/A (Digital Format)
Paper Type
Paper Type:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Primary Engine:
Liquid-cooled, 2-stroke, single-cylinder
Engine Details
Engine Details:
Typically features a reed valve induction, possibly with a power valve (A.E.S. - Aprilia Exhaust System) for improved torque and power delivery across the rev range. Displacement is 49.3 cc.
Performance
Horsepower:
Approx. 6.4 hp (4.7 kW) @ 8000 rpm (typically restricted for legal 50cc classes, de-restricted potential higher)
Torque:
Approx. 5.0 Nm (3.7 lb-ft) @ 7500 rpm (estimated)
Fuel System
Fuel System:
Carbureted. Typically uses a Dell'Orto PHVA 17.5 or similar 17.5mm carburetor.
Ignition
Ignition System:
Electronic CDI (Capacitor Discharge Ignition)
Cooling System
Cooling System:
Liquid-cooled, with a front-mounted radiator and fan.
Lubrication
Lubrication System:
Premix (fuel/oil mixture) or separate oil injection system.
Bore X Stroke
Bore X Stroke:
Approx. 39.5 mm x 40.0 mm
Compression Ratio
Compression Ratio:
Approx. 8.5:1 (typical for this class, varies with de-restriction)
🔧 Transmission
Standard
Transmission Type:
6-speed manual sequential gearbox
Features
Clutch Type:
Wet multi-plate clutch
Final Drive:
Chain drive
Gear Ratios:
Specific ratios are detailed within the manual, crucial for performance tuning and maintenance.
📐 Dimensions
Exterior
Length:
Approx. 1940 mm (76.4 in)
Width:
Approx. 710 mm (28.0 in) at handlebars
Height:
Approx. 1040 mm (40.9 in) at seat
Wheelbase:
Approx. 1360 mm (53.5 in)
Seat Height:
Approx. 810 mm (31.9 in)
Weights
Dry Weight:
Approx. 115 kg (253.5 lbs)
Fuel Tank Capacity:
Approx. 13 liters (3.4 US gal)
Oil Tank Capacity:
Approx. 1.5 liters (0.4 US gal) for separate injection systems
Coolant Capacity:
Approx. 0.8 liters (0.2 US gal)
🛡️ Safety Features
Ratings
Safety Ratings:
As a 50cc sportbike primarily for younger riders, formal crash test ratings like NCAP are not typically applicable. Safety relies on rider skill and adherence to traffic laws.
Active Features
Active Features:
Powerful front and rear disc brakes, capable suspension geometry for stability, responsive steering.
Passive Features
Passive Features:
Frame integrity, rider protective gear is paramount.
Braking System
Front Brake:
Single disc, hydraulic caliper (e.g., 280mm disc, 2-piston caliper)
Rear Brake:
Single disc, hydraulic caliper (e.g., 220mm disc, 1-piston caliper)
Tires
Front Tire Size:
110/70-17
Rear Tire Size:
130/70-17
Wheels
Wheel Type:
Cast aluminum alloy, 17-inch diameter
💡 Technology Features
Infotainment
Infotainment System:
N/A - This is a basic sportbike focused on performance and riding experience; no complex infotainment systems.
Instrumentation
Instrumentation:
Analog speedometer and tachometer, odometer, trip meter, coolant temperature warning light, neutral indicator, turn signal indicators, high beam indicator.
🔧 Maintenance
Service Intervals
Service Intervals:
Detailed schedules provided in the manual, typically including: Oil change/check (every few hundred km or monthly), Spark plug replacement (e.g., 3000-5000 km), Air filter cleaning/replacement (e.g., 3000-6000 km), Chain cleaning & lubrication (frequent, e.g., every 500 km), Brake fluid flush (e.g., annually), Coolant flush (e.g., every 2 years), Full engine service (e.g., 6000-10000 km). Specific intervals are critical and are detailed in the manual.
Fluid Specifications
Engine Oil Type:
2-stroke engine oil (specific API TC, JASO FD or higher specification, often recommended as semi-synthetic or fully synthetic for performance). The manual will specify the exact grade and standard. If separate oil injection, Aprilia brand or equivalent 2T oil is recommended.
Coolant Type:
Ethylene glycol based antifreeze coolant (e.g., 50/50 mix with distilled water). Manual will specify color and type.
Brake Fluid Type:
DOT 4 brake fluid.
Gearbox Oil Type:
Specific 2-stroke gearbox oil (e.g., SAE 75W/80 or 80W/90 GL-4). Capacity approx. 0.6 - 0.8 liters.
Known Issues
Common Issues:
Carburetor tuning sensitivity, exhaust port clogging (especially with aggressive premix or short-distance use), potential for stator/ignition coil failure, wear on the power valve mechanism (if equipped), rear shock absorber degradation over time, and general wear and tear on suspension components and bearings due to the bike's sporty nature.
Spark Plug
Spark Plug Recommendation:
NGK BR9EG or similar, with specific gap (e.g., 0.7-0.8 mm) detailed in manual.
Air Filter
Air Filter Type:
Foam or paper element, depending on original specification.
📚 Vehicle History
Brand Heritage
Brand Heritage:
Aprilia, an Italian manufacturer, has a rich history in motorcycle racing, particularly in smaller displacement classes like 125cc and 250cc Grand Prix, as well as success in Supermoto and World Superbike. This racing pedigree heavily influenced the design and engineering of their road-going sportbikes, including the RS50.
Model Evolution
Model Evolution:
The RS50 model line evolved through several iterations. The 1999-2005 period covers a significant generation that refined the original design, often featuring updated styling and minor mechanical improvements. Later models saw changes in engine specifications (e.g., more advanced engine management or emission controls depending on market) and aesthetics. The manual covers a specific, well-regarded era of this model's development.
Production
Production Years:
1999-2005 for this specific manual coverage. The RS50 model line itself has had a longer production run, with significant redesigns in later years.
Manufacturing Location:
Italy
🏆 Awards & Recognition
Recognitions
Recognitions:
While specific awards for the 1999-2005 RS50 generation are not widely publicized, the model was consistently praised in enthusiast and motorcycle media of its time for its class-leading handling, braking, and premium feel, often being considered the benchmark 50cc sportbike.
Ratings
Enthusiast Ratings:
Highly regarded by owners and reviewers for its authentic supersport experience and build quality, making it a desirable machine for young riders and collectors.
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