Aprilia RS50 RS 50 1999-2010 Service Repair Workshop Manual
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🏷️ Basic Information Identification Make: Aprilia Model: RS50 Model Years Covered: 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010 Codes Internal Code: RS50_99_10_SRWM 👋 Introduction Market Position Target Audience: Aprilia RS50 owners, independent repair shops, motorcycle technicians, and DIY enthusiasts Competitive Analysis Value Proposition: Provides factory-level diagnostic and repair procedures, enabling significant cost savings on maintenance and repairs compared to dealership service. Key Features Content Quality: Contains accurate, clear, and concise text with detailed diagrams, illustrations, and wiring schematics. Authenticity: Vehicle-specific information, mirroring the exact content used by authorized dealer service departments. Accessibility: Digital format allows for easy access and printing of specific pages, protecting the original manual from wear and tear. 📋 Manual Details Coverage Areas Coverage Scope: Comprehensive Service, Repair, and Workshop Procedures Page Count Estimated Page Count: Varies (Typically 300-600 pages for comprehensive manuals of this era) Manual Type Type: Service Repair Workshop Manual Type Details: Factory authorized service manual, providing complete diagnostic and repair procedures. Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Engine: Engine disassembly, assembly, troubleshooting, tuning, components (cylinder, piston, crankshaft, bearings), lubrication, cooling system Fuel System: Carburetor(s) servicing and adjustment, fuel pump, fuel lines, fuel tank, fuel filter replacement Cooling System: Radiator, coolant hoses, water pump, thermostat, coolant specifications and bleeding procedures Electrical System: Wiring schematics, battery, charging system (stator, regulator/rectifier), ignition system (CDI, spark plug), lighting, instrumentation, starter system Body Work: Fairings, seat, fuel tank, fenders, handlebars, mirrors, frame components, fasteners Suspension: Front fork (telescopic), rear shock absorber, swingarm, suspension adjustments, seal replacement Brakes: Front and rear brake systems (hydraulic disc), brake fluid specifications, caliper servicing, pad replacement, bleeding procedures, master cylinder Wheels And Tires: Wheel bearings, tire inspection and replacement, wheel balancing, rim specifications Exhaust System: Exhaust pipe, muffler, gasket replacement, emissions control (if applicable) Chassis: Frame inspection, swingarm maintenance, steering head bearing servicing. Fuel Delivery: Details on the oil injection system (if equipped), including pump operation and lubrication. Gearbox: Gearbox disassembly, inspection, and reassembly procedures, including gear ratios and shift mechanism. Procedures Included Maintenance: Routine maintenance, oil changes, filter replacements, chain adjustment, lubrication points, spark plug checks Troubleshooting: Diagnostic procedures for common and uncommon issues, symptom-based troubleshooting guides Repair: Step-by-step repair instructions for all major components and systems Diagnostics: Detailed diagnostic trees and explanations for electrical and mechanical faults Specifications: Torque specifications, clearances, fluid capacities, electrical resistance values, performance data Installation: Instructions for installing aftermarket parts or replacing major assemblies may be included or alluded to. Rebuilds: Detailed procedures for engine rebuilds, including piston, ring, and crankshaft bearing replacement. Tuning: Guidance on engine tuning parameters, carburetor jetting, and ignition timing adjustments. Technical Depth Depth: Factory-level repair and diagnostic information suitable for professional mechanics and experienced DIY enthusiasts Illustrations: Includes numerous diagrams and illustrations to visually guide the user through procedures. 📊 Manual Specifications File Format Compatibility: Compatible with all versions of Windows and macOS Download Speed: Optimized for speed download. Print Quality Printability: Fully printable, allowing for individual page printing as needed Binding Type Binding: Not Applicable (Digital Format) Paper Type Paper Type: Not Applicable (Digital Format) Digital Features Searchability: Searchable text within the PDF document Viewing Devices: Viewable on PC, Mac, tablets, smartphones, and e-readers (e.g., Kindle) ⚙️ Engine Specifications Primary Engine Type: Two-stroke, single-cylinder Cooling Method: Liquid-cooled Displacement: Typically around 49cc (specifics may vary slightly by sub-model or region) Performance Horsepower Range: Approximately 8-15 HP (subject to local regulations and specific model tuning) Fuel System Carburetor Details: Commonly equipped with Dell'Orto or similar performance carburetors (e.g., PHVA 17.5) Fuel Type: Unleaded gasoline mixed with two-stroke oil (pre-mix or oil injection system) 🔧 Transmission Standard Type: 6-speed manual transmission Features Clutch Type: Wet, multi-plate clutch 📐 Dimensions Exterior Wheelbase: Typically around 1370 mm (53.9 inches) Weights Dry Weight: Approximately 110-120 kg (242-265 lbs) 🛡️ Safety Features Active Features Braking System: Hydraulic disc brakes front and rear Passive Features Frame Construction: Aluminum twin-spar frame for rigidity and light weight 💡 Technology Features Infotainment Instrumentation: Digital and analog instrument cluster including speedometer, tachometer, odometer, trip meter, and indicator lights. Driver Assistance N A: N/A for this model (primarily mechanical systems). Connectivity N A: N/A for this model. 🔧 Maintenance Service Intervals Oil Change Interval: Refer to manual for specific intervals, typically every 3000-5000 km (2000-3000 miles) for engine oil (if applicable for gearbox oil) and every 100 hours for gearbox oil. Spark Plug Replacement: Every 5,000-10,000 km (3,000-6,000 miles) or as per manual recommendations. Fluid Specifications Engine Oil Type: High-quality 100% synthetic two-stroke engine oil, specific grade as per Aprilia recommendations (e.g., SAE 10W-30 for gearbox oil). Coolant Type: Ethylene glycol-based antifreeze/coolant with corrosion inhibitors, mixed with distilled water (typically 50/50 ratio). Brake Fluid Type: DOT 4 or DOT 5.1 hydraulic brake fluid (check manual for exact specification). Known Issues Carburetor Fouling: Can...
Diagnostic procedures for common and uncommon issues, symptom-based troubleshooting guides
Repair:
Step-by-step repair instructions for all major components and systems
Diagnostics:
Detailed diagnostic trees and explanations for electrical and mechanical faults
Specifications:
Torque specifications, clearances, fluid capacities, electrical resistance values, performance data
Installation:
Instructions for installing aftermarket parts or replacing major assemblies may be included or alluded to.
Rebuilds:
Detailed procedures for engine rebuilds, including piston, ring, and crankshaft bearing replacement.
Tuning:
Guidance on engine tuning parameters, carburetor jetting, and ignition timing adjustments.
Technical Depth
Depth:
Factory-level repair and diagnostic information suitable for professional mechanics and experienced DIY enthusiasts
Illustrations:
Includes numerous diagrams and illustrations to visually guide the user through procedures.
📊 Manual Specifications
File Format
Compatibility:
Compatible with all versions of Windows and macOS
Download Speed:
Optimized for speed download.
Print Quality
Printability:
Fully printable, allowing for individual page printing as needed
Binding Type
Binding:
Not Applicable (Digital Format)
Paper Type
Paper Type:
Not Applicable (Digital Format)
Digital Features
Searchability:
Searchable text within the PDF document
Viewing Devices:
Viewable on PC, Mac, tablets, smartphones, and e-readers (e.g., Kindle)
⚙️ Engine Specifications
Primary Engine
Type:
Two-stroke, single-cylinder
Cooling Method:
Liquid-cooled
Displacement:
Typically around 49cc (specifics may vary slightly by sub-model or region)
Performance
Horsepower Range:
Approximately 8-15 HP (subject to local regulations and specific model tuning)
Fuel System
Carburetor Details:
Commonly equipped with Dell'Orto or similar performance carburetors (e.g., PHVA 17.5)
Fuel Type:
Unleaded gasoline mixed with two-stroke oil (pre-mix or oil injection system)
🔧 Transmission
Standard
Type:
6-speed manual transmission
Features
Clutch Type:
Wet, multi-plate clutch
📐 Dimensions
Exterior
Wheelbase:
Typically around 1370 mm (53.9 inches)
Weights
Dry Weight:
Approximately 110-120 kg (242-265 lbs)
🛡️ Safety Features
Active Features
Braking System:
Hydraulic disc brakes front and rear
Passive Features
Frame Construction:
Aluminum twin-spar frame for rigidity and light weight
💡 Technology Features
Infotainment
Instrumentation:
Digital and analog instrument cluster including speedometer, tachometer, odometer, trip meter, and indicator lights.
Driver Assistance
N A:
N/A for this model (primarily mechanical systems).
Connectivity
N A:
N/A for this model.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Refer to manual for specific intervals, typically every 3000-5000 km (2000-3000 miles) for engine oil (if applicable for gearbox oil) and every 100 hours for gearbox oil.
Spark Plug Replacement:
Every 5,000-10,000 km (3,000-6,000 miles) or as per manual recommendations.
Fluid Specifications
Engine Oil Type:
High-quality 100% synthetic two-stroke engine oil, specific grade as per Aprilia recommendations (e.g., SAE 10W-30 for gearbox oil).
Coolant Type:
Ethylene glycol-based antifreeze/coolant with corrosion inhibitors, mixed with distilled water (typically 50/50 ratio).
Brake Fluid Type:
DOT 4 or DOT 5.1 hydraulic brake fluid (check manual for exact specification).
Known Issues
Carburetor Fouling:
Can occur due to improper fuel/oil mixture, poor quality fuel, or infrequent use, leading to starting issues or poor running.
Power Valve Sticking:
Carbon buildup can cause the exhaust power valve to stick, affecting engine performance. Regular cleaning is recommended.
Cooling System Leaks:
Hose degradation or clamp failure can lead to coolant leaks, requiring prompt attention to prevent overheating.
📚 Vehicle History
Brand Heritage
Manufacturer:
Aprilia is an Italian manufacturer renowned for its sporty motorcycles, particularly in the small-displacement and racing categories.
Model Evolution
Positioning:
The RS50 was Aprilia's flagship model in the 50cc sportbike segment, designed to offer a premium experience with performance, styling, and handling that mimicked larger sportbikes.
Production
Production Period:
The RS50 platform saw continuous development and production throughout the covered period (1999-2010), with various minor updates and engine configurations.
🏆 Awards & Recognition
Recognitions
Industry Standing:
The Aprilia RS50 was highly regarded in its class for its racing-inspired design, performance, and handling, often considered a benchmark in the 50cc sportbike segment.