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Aprilia Rs50 Motorcycle Service Repair Manual 2004-2005

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🏷️ Basic Information Identification Make: Aprilia Model: RS 50 Generation Generation Code: Second Generation (AM/FG) Codes Chassis Code: AM6 Engine Variants 👋 Introduction Market Position Class: Lightweight Sportbike / Moped...
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Type: Motorcycle
Vendor:
Sku: 602467
Aprilia Rs50 Motorcycle Service Repair Manual 2004-2005
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
RS 50
Generation
Generation Code:
Second Generation (AM/FG)
Codes
Chassis Code:
AM6 Engine Variants
👋 Introduction
Market Position
Class:
Lightweight Sportbike / Moped
Target Audience:
Enthusiasts, learners, urban commuters
Competitive Analysis
Key Competitors:
Derbi GPR 50, Gilera SMT/RCR 50, Yamaha TZR 50, Honda RS 50 (older models)
Key Features
Design Philosophy:
Replicates the styling and performance characteristics of larger Aprilia sportbikes.
Engine Type:
Liquid-cooled, two-stroke, single-cylinder
📋 Manual Details
Coverage Areas
Applicable Years:
2004, 2005
Page Count
Total Pages:
Approx. 450+
Manual Type
Type:
Factory Service Manual
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete overhaul, timing, valve clearance, piston/cylinder inspection, crankshaft assembly, lubrication system.
Engine Fuel System:
Carburetor tuning and overhaul (Dell'Orto PHBN/PHVA variants), fuel pump, fuel lines, fuel filter replacement.
Engine Ignition System:
Ignition timing, spark plug specifications, CDI unit, stator and rotor testing, wiring diagrams.
Exhaust System:
Exhaust pipe, silencer removal and installation, gasket replacement.
Cooling System:
Radiator, coolant, water pump, thermostat, bleeding procedure, hoses.
Transmission Drivetrain:
Clutch operation and adjustment, gearbox internal components, gear selection mechanism, chain and sprocket maintenance.
Frame Chassis:
Frame inspection, front fork assembly and adjustment, rear shock absorber, swingarm maintenance.
Braking System:
Front and rear brake caliper overhaul, master cylinder inspection, brake fluid replacement, bleeding procedures, pad and disc replacement.
Electrical System:
Battery maintenance, lighting system, starter motor, horn, wiring harness diagrams, fuse identification and replacement.
Wheels Tires:
Wheel bearing inspection and replacement, tire pressure specifications, wheel balancing.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, chain lubrication, brake adjustments, tire checks.
Troubleshooting:
Diagnostic charts for common starting, running, and electrical issues.
Component Overhaul:
Detailed step-by-step instructions for rebuilding key engine and transmission components.
Adjustment Calibration:
Carburetor synchronization, clutch lever play, brake lever free play, suspension settings.
Wiring Diagrams:
Comprehensive color-coded electrical schematics for all major systems.
Technical Depth
Depth:
Comprehensive (from basic maintenance to full engine rebuilds and electrical diagnostics).
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Fully searchable text
Print Quality
Resolution:
High resolution for clarity of diagrams and text
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Code:
Minarelli AM6
Displacement:
49.7 cc
Bore X Stroke:
39.3 mm x 40.3 mm
Compression Ratio:
Approx. 8.5:1 (stock)
Ignition:
Electronic CDI
Lubrication:
Pre-mix or separate oil injection system
Cooling System:
Liquid-cooled
Performance
Horsepower:
Approx. 7-8 HP (restricted for license compliance)
Torque:
Approx. 5-6 Nm
Fuel System
Carburetor Type:
Dell'Orto PHBN 14 or PHVA 17.5 (depending on market/version)
Fuel Type:
Unleaded gasoline (95 RON recommended)
🔧 Transmission
Standard
Transmission Type:
6-speed manual
Features
Clutch Type:
Wet multi-plate
Final Drive:
Chain drive
📐 Dimensions
Exterior
Length:
Approx. 1940 mm
Width:
Approx. 710 mm
Height:
Approx. 1125 mm
Wheelbase:
Approx. 1350 mm
Weights
Dry Weight:
Approx. 105 kg
Fuel Tank Capacity:
Approx. 13 Liters
🛡️ Safety Features
Ratings
Crash Safety:
N/A (Motorcycle specific ratings not applicable in traditional automotive sense)
Active Features
Brakes:
Hydraulic disc brakes front and rear.
Suspension:
Adjustable front forks, monoshock rear suspension for improved handling and stability.
Passive Features
Lighting:
Headlight, taillight, brake light, turn signals.
💡 Technology Features
Infotainment
Display:
Analog speedometer, tachometer, and indicator lights.
Driver Assistance
ABS:
Not equipped with ABS.
Connectivity
Bluetooth Usb:
No integrated connectivity features.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Check level daily, change as per manual recommendations (typically every 3,000-5,000 km or annually).
Spark Plug:
Inspect/replace every 3,000-5,000 km.
Air Filter:
Clean/inspect every 2,000 km, replace as needed.
Chain Maintenance:
Lubricate and adjust tension every 500 km.
Fluid Specifications
Engine Oil Type:
Two-stroke premix oil (specific API TC, JASO FD rated)
Coolant Type:
Ethylene glycol-based coolant with corrosion inhibitors (50% mixture with distilled water).
Brake Fluid Type:
DOT 4
Known Issues
Carburetor Tuning:
Can be sensitive to altitude and atmospheric changes, requiring periodic adjustment.
Starter Clutch:
Early models or high-mileage bikes may experience wear in the starter clutch mechanism.
Exhaust Leaks:
Gasket wear between cylinder and exhaust manifold can lead to leaks.
Electrical Connectors:
Corrosion or looseness in connectors can cause intermittent electrical issues.
📚 Vehicle History
Brand Heritage
Manufacturer Origin:
Aprilia is an Italian manufacturer known for its racing pedigree and performance motorcycles.
Model Evolution
Rs50 Lineage:
The RS 50 has been a staple in Aprilia's entry-level sportbike lineup, evolving through various iterations focusing on styling and performance within the 50cc segment.
Key Changes 2004-2005:
This generation (often referred to as the 'AM' or 'FG' platform) featured updated styling, revised chassis components, and refinements to the ubiquitous Minarelli AM6 engine.
Production
Manufacturing Location:
Italy
🏆 Awards & Recognition
Recognitions
Sportbike Segment:
Recognized as a popular choice for entry-level sportbike enthusiasts due to its styling and accessible performance.
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