Aprilia RS50 2003 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Aprilia Model: RS50 Year: 2003 Product Name: Aprilia RS50 2003 Factory Service Repair Manual Generation Generation Designation: Second Generation (AM/EB Series) Codes Chassis Code Common:...

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类型: Motorcycle

斯库: 602473

标签: 2003 Aprilia Featured Motorcycle Motorcycles RS Models RS50

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Description

🏷️ Basic Information

Identification

Make:

Aprilia

Model:

Year:

Product Name:

Aprilia RS50 2003 Factory Service Repair Manual

Generation

Generation Designation:

Second Generation (AM/EB Series)

Codes

Chassis Code Common:

AM/EB

👋 Introduction

Market Position

Market Segment:

Entry-level sport motorcycle, popular among younger riders and for A1 license holders.

Competitive Analysis

Competitors 2003:

Yamaha TZR50, Derbi GPR50, Honda RS50 (non-Aprilia).

Key Features

Design Philosophy:

Mimics the styling and performance characteristics of larger Aprilia sportbikes, offering a premium feel in the 50cc class.

Performance Emphasis:

Focused on sporty handling and responsive acceleration typical of Aprilia's performance heritage.

📋 Manual Details

Coverage Areas

Engine Coverage:

Complete engine disassembly, assembly, tuning, and troubleshooting for the 50cc 2-stroke engine.

Transmission Coverage:

Detailed procedures for gearbox inspection, repair, and replacement, including clutch operation.

Electrical Coverage:

Wiring diagrams, component testing, ignition system diagnosis, lighting, and starter system.

Chassis Coverage:

Frame, suspension (front forks, rear shock), steering, brakes (front and rear discs), wheels, and tires.

Bodywork Coverage:

Fairings, seat, fuel tank, and associated fasteners and trim removal/installation.

Page Count

Estimated Pages:

Manual Type

Type:

Factory Service Repair Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

All Systems:

Engine, Fuel System, Lubrication, Ignition, Cooling, Exhaust, Transmission, Drivetrain, Chassis, Suspension, Brakes, Electrical System, Bodywork, Maintenance, Troubleshooting.

Procedures Included

Maintenance Procedures:

Oil changes, spark plug replacement, air filter cleaning/replacement, chain adjustment, brake bleeding, coolant flush.

Repair Procedures:

Engine rebuilds, carburetor tuning, suspension overhaul, brake caliper service, electrical component replacement.

Troubleshooting Guides:

Step-by-step diagnostic flowcharts for common starting, running, and electrical issues.

Technical Depth

Depth:

Comprehensive. Covers everything from basic owner maintenance to full engine rebuilds and advanced electrical diagnostics.

📊 Manual Specifications

File Format

PDF Quality:

High-resolution scans with searchable text for easy navigation and printing.

Print Quality

Print Readability:

Designed for clarity and ease of use when printed, with crisp diagrams and readable text.

Binding Type

Binding Description:

N/A (Digital PDF)

Paper Type

Paper Description:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Liquid-cooled, 2-stroke, single-cylinder

Displacement:

49.7 cc

Bore X Stroke:

39.5 mm x 40.0 mm

Compression Ratio:

8.3:1

Power Output Claimed:

~8.4 HP (6.3 kW) @ 9000 rpm (may vary based on region/derestriction)

Torque Output Claimed:

~6.7 Nm (4.9 lb-ft) @ 8500 rpm (may vary)

Performance

Top Speed Derestricted:

~70 mph (110 km/h) (subject to rider weight, conditions, and tuning)

Fuel System

Carburetor:

Dell'Orto PHBN 17.5 DS (or similar variant)

Fuel Type:

Unleaded gasoline (minimum 95 RON recommended)

Fuel Tank Capacity:

13 Liters (approx. 3.4 US gallons)

Oil Mixture:

Pre-mix or separate oil injection system (manual specifies correct ratio/operation)

Engine Components

Cylinder Material:

Aluminum alloy with cast-iron liner

Crankshaft Type:

Full circle, roller bearing supported

🔧 Transmission

Standard

Transmission Type:

6-speed constant mesh gearbox

Features

Clutch Type:

Wet multi-plate clutch, cable operated

Final Drive:

Chain driven (520 pitch typical)

Fluid Specifications

Gearbox Oil Type:

API GL-4, SAE 75W/90 or 10W/40 motorcycle gear oil (refer to manual for exact specs)

Gearbox Oil Capacity:

Approx. 0.8 Liters (check dipstick/level plug)

📐 Dimensions

Exterior

Length:

Approx. 1950 mm

Width:

Approx. 720 mm (at handlebars)

Height:

Approx. 1070 mm (at handlebars)

Wheelbase:

Approx. 1340 mm

Seat Height:

Approx. 820 mm

Weights

Dry Weight:

Approx. 115 kg

Gross Vehicle Weight Rating Gvwr:

Not explicitly specified, typical for a 50cc light motorcycle.

Wheels Tires

Front Wheel Size:

17 inches

Rear Wheel Size:

17 inches

Front Tire Size:

110/70-17

Rear Tire Size:

130/70-17

Wheel Bolt Pattern:

N/A (typically single-sided hub or specific caliper mounting)

🛡️ Safety Features

Ratings

Crash Test Results:

N/A (Motorcycles are not typically subjected to the same crash testing standards as cars).

Active Features

Braking System:

Hydraulic disc brakes front and rear.

Front Brake Spec:

Single disc, hydraulic caliper (e.g., Brembo or similar quality)

Rear Brake Spec:

Single disc, hydraulic caliper

Passive Features

Lighting System:

Halogen headlight, LED tail/brake lights, turn signals.

Frame Construction:

Aluminum twin-spar frame (often referred to as Delta Box style or similar).

💡 Technology Features

Infotainment

Infotainment System:

N/A (Basic analog instrumentation: speedometer, tachometer, odometer, neutral indicator, turn signals).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Refer to manual; typically every 2,000-3,000 km for gearbox oil.

Spark Plug Replacement Interval:

Refer to manual; typically every 5,000-8,000 km or as needed based on condition.

Air Filter Maintenance:

Clean/inspect every 1,000-2,000 km, replace as needed. Use specific foam cleaner/oil for foam filters.

Chain Adjustment Interval:

Inspect and adjust chain slack every 500-1,000 km, or as required.

Fluid Specifications

Coolant Type:

Ethylene glycol based coolant, 50% concentration with distilled water. (Refer to manual for specific type/color if required)

Brake Fluid Type:

DOT 4 brake fluid.

Known Issues

Common Wear Items:

Clutch plates, piston rings, spark plugs, chain and sprockets, fork seals due to age and typical usage.

Carburetor Tuning Sensitivity:

Carburetors can be sensitive to altitude, temperature, and exhaust/intake modifications, often requiring tuning.

Electrical Connections:

Corrosion or loosening of electrical connectors, especially on older models, can cause intermittent faults.

📚 Vehicle History

Brand Heritage

Aprilia Legacy:

Aprilia has a strong racing heritage in Grand Prix motorcycle racing, particularly in smaller displacement classes, which influences their road bike designs.

Model Evolution

Rs50 Generations:

The RS50 has seen several iterations, with the 2003 model representing the second generation, known for its significant styling and chassis updates over the original model.

Production

Manufacturing Location:

Italy

Production Period:

The RS50 was in production for many years, with the AM/EB series (including 2003) being prominent from the late 1990s into the mid-2000s.

🏆 Awards & Recognition

Recognitions

Design Awards:

N/A specifically documented, but the RS50's styling was considered a benchmark in its class.

Ratings

Performance Reviews:

Generally well-regarded for its sporty handling, strong braking, and authentic supersport styling, making it a desirable entry-level machine.

Certifications

Emissions Standards:

Compliant with European emissions standards relevant to its production year (e.g., Euro 1 or Euro 2 depending on specific variant/market).