Aprilia RS50 RS50 1999 Service Repair Workshop Manual
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🏷️ Basic Information Identification Make: Aprilia Model: RS50 Year: 1999 Codes Chassis Code: AM6 👋 Introduction Market Position Segment: Lightweight sport motorcycle, entry-level performance segment. Target Audience: Young riders, new motorcyclists, riders seeking a nimble and sporty experience, often for track days or spirited street riding. Competitive Analysis Key Competitors: Yamaha TZR50, Aprilia RS 125 (larger displacement), Derbi GPR50, Cagiva Mito 50, Honda NSR50 (market dependent). Key Features Styling: Aggressive sportbike styling, often mimicking larger Aprilia racing models. Performance Orientation: Designed for sporty handling and a responsive riding experience despite its small displacement. Engine Basis: Utilizes the robust and popular Minarelli AM6 engine, known for its tunability and widespread aftermarket support. 📋 Manual Details Coverage Areas Manual Type: Service Repair Workshop Manual Language: English Format: Digital (likely PDF) Page Count Estimated Page Count: 300+ 📖 Manual Coverage Systems Covered Engine Mechanical: Complete engine disassembly, assembly, tuning, carburetor adjustment, cooling system maintenance, lubrication. Engine Electrical: Ignition system, stator, CDI unit, spark plug, wiring diagrams, troubleshooting electrical faults. Transmission: Gearbox inspection, clutch maintenance, gear shift mechanism, lubrication. Chassis: Frame inspection, suspension (front forks, rear shock absorber) overhaul and adjustment, steering head bearings. Brakes: Front and rear brake system maintenance, bleeding, caliper overhaul, pad replacement, fluid specifications. Fuel System: Fuel tank, fuel lines, fuel pump (if applicable), carburetor specifications and tuning (Dell'Orto PHBG series common). Exhaust System: Exhaust pipe and silencer inspection, gasket replacement. Cooling System: Radiator, coolant hoses, thermostat, coolant specifications and maintenance. Wheels Tires: Wheel bearing maintenance, tire pressure, rim specifications. Bodywork Plastics: Fairing removal and installation, seat, tank cover. Procedures Included Preventative Maintenance: Regular checks, lubrication points, filter replacement, chain adjustment, spark plug replacement. Troubleshooting: Diagnostic procedures for common starting issues, running problems, electrical faults, and mechanical noises. Repair Procedures: Step-by-step guides for engine rebuilds, clutch replacement, suspension service, brake caliper overhauls, and electrical component repairs. Adjustment Procedures: Carburetor tuning (idle speed, mixture), ignition timing (if adjustable), clutch lever free play, suspension preload. Disassembly Assembly: Detailed instructions for dismantling and reassembling all major components and sub-assemblies. Technical Depth Depth Of Coverage: Comprehensive. Covers everything from basic owner-level maintenance to advanced engine rebuilding and electrical diagnostics. Diagnostic Charts: Likely includes diagnostic flowcharts for troubleshooting common issues. Torque Specifications: Crucial torque values for all fasteners throughout the motorcycle. Clearances Tolerances: Specifications for valve clearances, piston ring gap, bearing tolerances, etc. Special Tools: Lists and descriptions of specialized tools required for certain procedures. 📊 Manual Specifications File Format Digital Format: PDF (Portable Document Format) - typically high-resolution scans or digital originals. Searchable: Yes, usually text-searchable for keywords. Printable: Yes, printable pages. Print Quality Image Resolution: High resolution, ensuring clarity of diagrams and text. Binding Type Physical Manual Binding: N/A (Digital format, but if printed, would typically be bound for durability). Paper Type Physical Manual Paper: N/A (Digital format, but original manuals were often on durable paper). ⚙️ Engine Specifications Primary Engine Engine Type: 2-stroke, single-cylinder Displacement: 49.7 cc Bore X Stroke: 39.5 mm x 40.3 mm (typical for AM6) Cooling System: Liquid-cooled Valves: Reed valve induction Performance Horsepower: Approximately 7-10 HP (stock, depending on market and power restrictions) Torque: Approximately 5-7 Nm (stock) Fuel System Carburetor Model: Dell'Orto PHBG 19 (common, but variations exist) Fuel Type: Unleaded gasoline, minimum 95 octane recommended (with 2-stroke oil pre-mix or separate oil injection system) Oil Type: High-quality 2-stroke synthetic or semi-synthetic oil (for pre-mix or oil injection) 🔧 Transmission Standard Transmission Type: 6-speed manual Clutch Type: Wet multi-plate Features Gear Ratios: Specific gear ratios would be detailed in the manual, crucial for performance tuning. Final Drive: Chain drive 📐 Dimensions Exterior Length: Approximately 1950 mm Width: Approximately 720 mm Height: Approximately 1140 mm Weights Dry Weight: Approximately 115 kg Fuel Capacity: Approximately 13 liters Wheelbase: Approximately 1360 mm 🛡️ Safety Features Ratings Safety Standards: Complies with relevant European motorcycle safety standards for its class and year. Active Features Braking System: Disc brakes front and rear for effective stopping power. Passive Features Frame Construction: Durable aluminum twin-spar frame for rigidity and handling. Lighting: Full lighting system including headlights, taillights, and turn signals for visibility. 💡 Technology Features Infotainment Infotainment System: N/A (No advanced infotainment systems on this model; focus is on core motorcycle mechanics). Driver Assistance Driver Assistance Features: N/A (No electronic rider aids like ABS or traction control on this model). Connectivity Connectivity Features: N/A (No digital connectivity features). 🔧 Maintenance Service Intervals Oil Change Interval: Depending on usage, check oil level frequently. Oil injection system filter and pump checks at specified intervals. Spark Plug Replacement: Every 3,000-5,000 km or as needed, depending on plug type and usage. Air Filter Cleaning Replacement: Check and clean every 2,000-3,000 km, replace as needed. Coolant Flush: Every 2 years or as recommended by coolant manufacturer. Brake Fluid Flush: Every 1-2 years. Fluid Specifications Engine Oil Type: High-quality 2-stroke synthetic...
Detailed instructions for dismantling and reassembling all major components and sub-assemblies.
Technical Depth
Depth Of Coverage:
Comprehensive. Covers everything from basic owner-level maintenance to advanced engine rebuilding and electrical diagnostics.
Diagnostic Charts:
Likely includes diagnostic flowcharts for troubleshooting common issues.
Torque Specifications:
Crucial torque values for all fasteners throughout the motorcycle.
Clearances Tolerances:
Specifications for valve clearances, piston ring gap, bearing tolerances, etc.
Special Tools:
Lists and descriptions of specialized tools required for certain procedures.
📊 Manual Specifications
File Format
Digital Format:
PDF (Portable Document Format) - typically high-resolution scans or digital originals.
Searchable:
Yes, usually text-searchable for keywords.
Printable:
Yes, printable pages.
Print Quality
Image Resolution:
High resolution, ensuring clarity of diagrams and text.
Binding Type
Physical Manual Binding:
N/A (Digital format, but if printed, would typically be bound for durability).
Paper Type
Physical Manual Paper:
N/A (Digital format, but original manuals were often on durable paper).
⚙️ Engine Specifications
Primary Engine
Engine Type:
2-stroke, single-cylinder
Displacement:
49.7 cc
Bore X Stroke:
39.5 mm x 40.3 mm (typical for AM6)
Cooling System:
Liquid-cooled
Valves:
Reed valve induction
Performance
Horsepower:
Approximately 7-10 HP (stock, depending on market and power restrictions)
Torque:
Approximately 5-7 Nm (stock)
Fuel System
Carburetor Model:
Dell'Orto PHBG 19 (common, but variations exist)
Fuel Type:
Unleaded gasoline, minimum 95 octane recommended (with 2-stroke oil pre-mix or separate oil injection system)
Oil Type:
High-quality 2-stroke synthetic or semi-synthetic oil (for pre-mix or oil injection)
🔧 Transmission
Standard
Transmission Type:
6-speed manual
Clutch Type:
Wet multi-plate
Features
Gear Ratios:
Specific gear ratios would be detailed in the manual, crucial for performance tuning.
Final Drive:
Chain drive
📐 Dimensions
Exterior
Length:
Approximately 1950 mm
Width:
Approximately 720 mm
Height:
Approximately 1140 mm
Weights
Dry Weight:
Approximately 115 kg
Fuel Capacity:
Approximately 13 liters
Wheelbase:
Approximately 1360 mm
🛡️ Safety Features
Ratings
Safety Standards:
Complies with relevant European motorcycle safety standards for its class and year.
Active Features
Braking System:
Disc brakes front and rear for effective stopping power.
Passive Features
Frame Construction:
Durable aluminum twin-spar frame for rigidity and handling.
Lighting:
Full lighting system including headlights, taillights, and turn signals for visibility.
💡 Technology Features
Infotainment
Infotainment System:
N/A (No advanced infotainment systems on this model; focus is on core motorcycle mechanics).
Driver Assistance
Driver Assistance Features:
N/A (No electronic rider aids like ABS or traction control on this model).
Connectivity
Connectivity Features:
N/A (No digital connectivity features).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Depending on usage, check oil level frequently. Oil injection system filter and pump checks at specified intervals.
Spark Plug Replacement:
Every 3,000-5,000 km or as needed, depending on plug type and usage.
Air Filter Cleaning Replacement:
Check and clean every 2,000-3,000 km, replace as needed.
Coolant Flush:
Every 2 years or as recommended by coolant manufacturer.
Brake Fluid Flush:
Every 1-2 years.
Fluid Specifications
Engine Oil Type:
High-quality 2-stroke synthetic or semi-synthetic oil (API TC, JASO FD, ISO-L-EGD)
Coolant Type:
Ethylene glycol based coolant, mixed 50/50 with distilled water.
Brake Fluid Type:
DOT 4 recommended
Transmission Oil Type:
API GL-3 or GL-4 gear oil (check specific viscosity, e.g., 75W/90 or 80W/90)
Known Issues
Carburetor Tuning Sensitivity:
Highly sensitive to altitude, temperature, and exhaust/cylinder modifications. Requires precise jetting.
Cooling System Leaks:
Potential for minor leaks from hoses or radiator connections if not maintained.
Electrical Connections:
Older models can sometimes have corroded electrical connectors if exposed to moisture. The manual will help diagnose these.
Power Band Tuning:
Achieving optimal performance often requires careful tuning of the exhaust, reeds, and carburetor.
📚 Vehicle History
Brand Heritage
Aprilia Legacy:
Aprilia has a strong heritage in motorcycle racing, particularly in smaller displacement categories, which influences the design and performance of models like the RS50.
Model Evolution
Rs50 Lineage:
The RS50 line has been a staple for Aprilia in the 50cc segment for many years, evolving through various design iterations and engine updates. The 1999 model represents a specific generation within this lineage.
Production
Manufacturing Location:
Italy
🏆 Awards & Recognition
Recognitions
Segment Awards:
While specific awards for the '99 RS50 might be obscure, the model series has historically been praised for its sporty appeal and handling in the 50cc class by motorcycle publications.
Ratings
Performance Ratings:
Generally rated highly for its class in terms of handling and aesthetics, often considered a benchmark for 50cc sportbikes of its era.
Certifications
Emissions Compliance:
Compliant with European emissions standards for 50cc motorcycles of its production year.
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