Aprilia RS50 1999-2010 Factory Service Repair Manual
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๐ท๏ธ Basic Information Identification Make: Aprilia Model: RS50 Year Range: 1999-2010 Codes Engine Type Code: RS50 (VDB00) ๐ Introduction Market Position Segment: Lightweight sport motorcycle (125cc class equivalent performance in its era). Target Audience: Young riders, commuters, track day enthusiasts seeking a sporty and agile machine. Competitive Analysis Key Competitors: Aprilia RS125 (larger displacement), Yamaha YZF-R125, Honda CBR125R, Suzuki GSX-R125. Key Features Design Philosophy: Race-inspired styling, aggressive ergonomics, performance-oriented chassis. Handling: Renowned for its sharp handling and agility, typical of Aprilia's racing heritage. ๐ Manual Details Coverage Areas Coverage Scope: Comprehensive Factory Service Repair Manual Page Count Estimated Page Count: 300+ Manual Type Type: Service and Repair Manual Language Language: English Format Format: Digital (PDF) ๐ Manual Coverage Systems Covered Engine Mechanical: Top-end overhaul, bottom-end assembly, cylinder head, piston, connecting rod, crankshaft, valve timing, lubrication system, cooling system. Fuel System: Carburetor identification, disassembly, cleaning, adjustment (Dell'Orto PHVA 12/17.5 series), fuel pump, fuel lines, fuel tank maintenance. Ignition System: CDI ignition, spark plug specifications, ignition timing, troubleshooting. Exhaust System: Muffler, expansion chamber, heat shields, gaskets, removal and installation procedures. Transmission: 6-speed gearbox, clutch operation, lubrication, disassembly, reassembly, gear shift mechanism. Chassis Frame: Frame inspection, weld integrity, steering head bearings, swingarm. Suspension Front: Telescopic fork specifications (Marzocchi/Paioli), oil type and level, seal replacement, fork leg disassembly. Suspension Rear: Monoshock absorber, linkage system, spring preload adjustment, shock absorber replacement. Braking System Front: Hydraulic disc brake, caliper specifications (Brembo/Grimeca), brake pad replacement, fluid type (DOT 4), bleeding procedure, master cylinder. Braking System Rear: Hydraulic disc brake, caliper specifications, brake pad replacement, fluid type, bleeding procedure. Wheels Tires: Wheel bearing inspection and replacement, tire size specifications, pressure recommendations, rim maintenance. Electrical System: Wiring diagrams, battery specifications, lighting system (headlight, taillight, indicators), horn, starter circuit. Bodywork: Fairing removal and installation, seat, fuel tank, fenders, graphics. Procedures Included Maintenance: Oil changes, filter replacements, chain adjustment, spark plug replacement, brake fluid flush, coolant checks. Troubleshooting: Diagnosing common starting issues, engine performance problems, electrical faults, braking system malfunctions. Repair: Engine rebuilds, carburetor tuning, suspension servicing, brake system overhauls, electrical component replacement. Diagnostics: Diagnostic charts for common issues, fault code interpretation (where applicable). Technical Depth Depth: Detailed technical specifications, step-by-step repair instructions, torque values, special tool recommendations. ๐ Manual Specifications File Format File Type: PDF Searchability: Fully searchable text for quick information retrieval. Print Quality Print Recommendation: High-resolution images and diagrams suitable for printing. Binding Type Digital Format Advantage: Instant download, accessible on multiple devices. Paper Type Digital Format Advantage: Environmentally friendly, no physical storage required. โ๏ธ Engine Specifications Primary Engine Make Model: Aprilia Rotax 2-stroke, single-cylinder Displacement: 49.4 cc Bore X Stroke: 39.5 mm x 40.3 mm Cooling System: Liquid-cooled Power Delivery: Typically around 6-8 hp at the crank (depending on market restrictions and specific year). Fuel System Carburetor Type: Dell'Orto PHVA 12 or 17.5 mm (depending on market/year) Fuel Type: Unleaded gasoline (min 95 RON) with 2-stroke oil mixture (e.g., 2% or 1:50). Engine Management Ignition: Electronic CDI (Capacitor Discharge Ignition) ๐ง Transmission Standard Type: 6-speed constant mesh, chain final drive Clutch: Wet multi-plate Features Gear Ratios: Specific ratios detailed in manual, typically optimized for sporty performance. ๐ Dimensions Exterior Length: Approx. 1990 mm (Varies slightly by year) Width: Approx. 720 mm (Varies slightly by year) Height: Approx. 1145 mm (Varies slightly by year) Wheelbase: Approx. 1360 mm Weights Dry Weight: Approx. 106 kg (Varies slightly by year) Fuel Tank Capacity: Approx. 13 Liters Wheels Tires Front Tire Size: 110/70-17 Rear Tire Size: 130/70-17 Wheel Type: Alloy wheels ๐ก๏ธ Safety Features Ratings Safety Certification: CE compliant for European markets. Active Features Brakes: Powerful hydraulic disc brakes front and rear. Lighting: Full lighting system including hazard lights (depending on market). Passive Features Frame Construction: Robust perimeter frame designed for high stability and control. Ergonomics: Sport riding position contributing to rider control. ๐ก Technology Features Infotainment Display: Analog tachometer and speedometer, basic indicator lights. Driver Assistance ABS: Not typically equipped with ABS. Connectivity Features: Basic electrical systems for lighting, ignition, and starting. ๐ง Maintenance Service Intervals Oil Change Engine: Every 3,000 km or annually (for gearbox oil). Spark Plug Replacement: Every 5,000 km or as needed based on inspection. Air Filter Cleaning: Every 2,000 km, replace as needed. Chain Lubrication: Every 500 km and after washing/rain. Brake Fluid Change: Every 2 years or as per manufacturer recommendation. Fluid Specifications Engine Oil Transmission: SAE 80W/90 GL-4 transmission oil. Capacity approx. 0.8-1.0 Liters (check manual for exact capacity). Coolant Type: Ethylene glycol based coolant with anti-corrosion additives. Typically a 50/50 mix with distilled water. Brake Fluid: DOT 4 hydraulic brake fluid. 2 Stroke Oil: High-quality synthetic 2-stroke oil, specifically for premix or separate injection systems. Known Issues Carburetor Wear: Common for older Dell'Orto carburetors to require periodic cleaning and jetting adjustments. Exhaust Leaks: Gasket seals between cylinder and expansion chamber can degrade...