APRILIA RS 50 Workshop Manual
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APRILIA RS 50 Workshop Manual

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Workshop manual

RS 50
979 X

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Summary of Contents for APRILIA RS 50

  • Page 1: Workshop Manual

    Workshop manual RS 50 979 X...
  • Page 2 This manual does not describe all of the procedures necessary to repair and service the vehicle in detail. This publication is intended for use by aprilia dealers Routine maintenance and their trained, experienced mechanics. The descriptions of many service and repair opera-...

  • Page 3: Table Of Contents

    RS 50 CONTENTS Chapter 1 POSITION OF SERIAL NUMBERS ....................... 1-2 SAFETY WARNINGS FOR FUEL, LUBRICANTS COOLANT AND OTHER COMPONENTS ....1-3 LUBRICANTS ............................1-5 RUNNING-IN RULES ..........................1-9 POSITION OF THE WARNING ADHESIVE LABELS ................1-10 SPARE PARTS ............................. 1-12 TECHNICAL DATA ..........................
  • Page 4 RS 50 FASTENERS ............................2-40 Chapter 3 ENGINE COMPONENTS THAT CAN BE REMOVED WITHOUT REMOVING THE ENGINE FROM THE FRAME ................... 3-2 REMOVING THE COMPLETE ENGINE FROM THE FRAME ............... 3-3 Chapter 4 FUEL TANK ............................4-2 MAINTENANCE ............................. 4-3 CHECKING THE FUEL FEED .......................
  • Page 5 RS 50 REMOVING THE LEFT HANDLEBAR HANDGRIP ................7-9 REMOVING THE LEFT HANDLEBAR ELECTRICAL CONTROLS ............7-9 REMOVING THE CLUTCH CONTROL ....................7-10 REMOVING THE THROTTLE CONTROL ................... 7-11 REMOVING THE RIGHT HANDLEBAR ELECTRICAL CONTROLS ..........7-12 REMOVING THE STOP SWITCH ......................7-12 REMOVING THE FRONT BRAKE CONTROL ..................
  • Page 6 RS 50 REAR WHEEL ............................. 7-58 REMOVING THE COMPLETE REAR WHEEL ..................7-59 REASSEMBLY REAR WHEEL ......................7-61 REAR BRAKE ............................7-63 CHANGING THE REAR BRAKE PADS ....................7-64 REMOVING THE REAR BRAKE DISC ....................7-65 REMOVING THE REAR BRAKE MASTER CYLINDER ..............7-65 REMOVING THE REAR SUSPENSION ....................
  • Page 7 RS 50 SAFETY WARNINGS Throughout this manual, you will see the following symbols: WARNING When you find this symbol on the vehicle or in the manual, this indicates that a potential for serious per- sonal injury or death exists. Failure to follow this warning may result in serious risk of personal injury or death, of the mechanic work- ing on the vehicle, the operator of the vehicle, or the general public.
  • Page 8 RS 50 USED ENGINE OIL AND FORK OIL WARNING Use latex glaves for the maintenance operations that require contact with used oil. Used oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is unlikely unless you handle used oil on a daily basis, it is advisable to thoroughly wash your hands with soap and water after handling used oil.
  • Page 9 RS 50 BATTERY HYDROGEN GAS AND ELECTROLYTE WARNING The battery gives off explosive gases; keep cigarettes, flames and sparks away from the battery. Provide adequate ventilation when operating or recharging the battery. The battery contains sulphuric acid (eloctrolyte). Contact with the skin or the eyes may cause serious burns.
  • Page 10 Bearings must turn freely with no sticking and/or noise. Replace bearings that show any roughness when the inner race is turned. Use only original aprilia Spare Parts for replacement. Use only the recommended lubricants and sealing agents. Lubricate all metal parts before refitting them. Pay particular attention to lubricate internal engine parts such as piston rings, valves, etc.
  • Page 11 RS 50 NOTES Release 00 2001-03...
  • Page 12 General information RS 50 General information ch. 1 Release 00 2001-03...

  • Page 13: Position Of Serial Numbers

    VEHICLE IDENTIFICATION NUMBER (V.I.N.) (FRAME NUMBER) Every motorcycle produced by aprilia receives a vehicle identification number (V. I. N.) stamped on the steering head of the frame (A), as shown above, and also on the identification plate (B) which is located on the front portion of the main frame.

  • Page 14: Safety Warnings For Fuel, Lubricants Coolant And Other Components

    General information RS 50 ENGINE NUMBER The engine number is stamped on the rear of the engine, next to the sprocket. SAFETY WARNINGS FOR FUEL, LUBRI- CANTS COOLANT AND OTHER COMPO- NENTS FUEL WARNING Gasoline is extremely flammable and in some conditions can become explosive.
  • Page 15 General information RS 50 Never try to siphon gasoline by sucking it with your mouth. Use a manual pump or a similar system. If your vehicle overturns, it will leak gasoline which is extremely flammable. Flames or sparks may ignite this which will not...

  • Page 16: Lubricants

    General information RS 50 LUBRICANTS WARNING Proper vehicle lubrication is critical to safe opera- tion. Failure to maintain proper lubricant levels or to use the proper type of clean, new lubricant, can lead to an engine or transmission seizure with subsequent accident, serious injury or death.
  • Page 17 General information RS 50 FORK OIL WARNING By changing the damper settings and/or the viscosity of the oil contained in them, the suspen- sion response may be altered partially. Standard oil viscosity: SAE 20 W. The viscosity ratings which can be chosen based on the type of fork stiffness desired (SAE 5W soft, 20W stiff).
  • Page 18 General information RS 50 BE SURE TO KEEP THE DRAINED COOLANT AWAY FROM CHILDREN AND PETS. IT IS SWEET TASTING, AS WELL AS EXTREMELY POISONOUS, AND IS VERY ATTRACTIVE TO CHILDREN AND PETS. Use extra caution not to spill the coolant on any hot parts of the engine.
  • Page 19 General information RS 50 On the basis of the desired freezing temperature of the coolant mixture, add to the water the percentage of coolant indicated in the following table. Freezing point Coolant °C (°F) % of volume -20° (-4°) -30° (-22°) -40°...

  • Page 20: Running-In Rules

    General information RS 50 WARNING Do not use fluids other than those specified and do not top up with different fluids, as this will damage the braking system. Do not use fluids that have been stored in old containers or that have been open for a long time.

  • Page 21: Position Of The Warning Adhesive Labels

    General information RS 50 POSITION OF THE WARNING ADHESIVE LABELS 10 11 12 1-10 ch. 1 Release 00 2001-03...
  • Page 22 Description WARNING! Do not use any tire other than those recommended and approved by Aprilia. Maintain proper tire inflation. So not use any tire with less than 1/8" (3mm) tread remainig. Do not repair any tire, nor use a repaired tire. Do not ride your motorcycle overloaded or with an unbalanced load.

  • Page 23: Spare Parts

    SPARE PARTS If any parts have to be replaced, use only original aprilia spare parts. aprilia original spare parts are high quality and have been designed and built specifically for aprilia motor cycles. WARNING The use of NON-original aprilia replacement parts may impair the motorcycle’s performance, and even can cause lasting damage.
  • Page 24 General information RS 50 GEAR RATIOS Ratio 2º 2 nd 16 / 33 = 1: 2.062 Secondary Total ratio 1:28.677 Ratio 3º 3 rd 19 / 29 = 1: 1.526 Secondary Total ratio 1:21.222 Ratio 4º 4 th 22 / 27 = 1: 1.227...

  • Page 25: Lubricant Chart

    General information RS 50 SPARK PLUG Standard NGK R BR9ES Alternative CHAMPION RN1C NGK R BR8ES Spark plug gap 0.6 - 0.7 mm (0.02 - 0.03 in) ELECTRIC Battery 12 V - 4 Ah Fuses 7.5 A Generator 12 V - 105 W...

  • Page 26: Special Tools

    General information RS 50 SPECIAL TOOLS Special service tools must be used for removing and fitting components correctly and for certain adjust- ments. The special tools will avoid the damage that can occur using unsuitable tools and/or improvised techniques. Below is the list of service tools specially designed for this specific motorcycle.
  • Page 27 General information RS 50 POSITIONING THE MOTORCYCLE ON THE REAR SUPPORT STAND Loosen the knob (1). Remove the front fork support (2) from the stand. Insert the support pin (3). Repeat the previous operations on the opposite side of the stand.

  • Page 28: General Specifications For Torque Wrench Settings

    General information RS 50 GENERAL SPECIFICATIONS FOR TORQUE WRENCH SETTINGS The standard torque wrench settings for screws and bolts with ISO metric thread are given in the table below. Thread Torque wrench Wrench screw or Nm (Ft-lb) bolt 6 (4.4) 15 (11.1)

  • Page 29: Abbreviations / Symbols / Initials

    General information RS 50 ABBREVIATIONS / SYMBOLS / INITIALS = number = liters < = less than = light emitting diode > = greater than = meters / second ≤ ≤ ≤ ≤ ≤ = equal to or less than = maximum ≥...
  • Page 30 Routine maintenance operations RS 50 Routine maintenance operations ch. 2 Release 00 2001-03...
  • Page 31 Routine maintenance operations RS 50 This section describes the routine maintenance procedures for the main components of the motor- cycle. CAUTION Before starting any maintenance or inspection job on the motorcycle, stop the engine and remove the key, and wait until the engine and exhaust system have cooled down.

  • Page 32: Chapter 2 Servicing Schedule

    C = check and clean, adjust, lubricate or replace if necessary; P = clean; S = replace; R = adjust. Service the motorcycle more frequently if it is used in rainy or dusty areas or on rough roads. Servicing of items marked (c) should be done ONLY by an authorized aprilia dealer. u = user c = dealer ch.

  • Page 33: Lubrication Points

    Routine maintenance operations RS 50 LUBRICATION POINTS KEY TO LUBRICATION DIAGRAM 1) Throttle control Regular, lubrication, using the correct lubricants, is an 2) Throttle cable important factor in ensuring the long life and excellent 3) Brake lever pin performance of the motorcycle.

  • Page 34: Arrangement Of The Instruments / Controls

    Routine maintenance operations RS 50 ARRANGEMENT OF THE INSTRUMENTS / CONTROLS 1) Ignition switch/ steering lock ( 2) Turn signal switch ( 3) Horn push button ( ) 4) Dimmer switch ( 5) High beam signalling push button ( )

  • Page 35: Battery

    Routine maintenance operations RS 50 BATTERY Read carefully (GENERAL PRECAUTIONS AND INFORMATION). Two types of batteries are sold for motorcycles: conventional, which has a removable cap on each cell, and maintenance free, which has no removable caps and cannot be inspected.

  • Page 36: Checking And Cleaning The Terminals

    Routine maintenance operations RS 50 If your battery needs to be charged, use a con- stant voltage, or “taper” charger, with a current rating no greater than 1/10th the capacity of the battery (i. e., for a 50 amp hour battery, the maxi- mum charging current should be 5 amps).

  • Page 37: Checking The Electrolyte Level

    Routine maintenance operations RS 50 CHECKING THE ELECTROLYTE LEVEL Read carefully (BATTERY). To check the electrolyte level, proceed as follows: Remove the battery (REMOVING THE BATTERY). Make sure that the fluid level falls between the “MIN” and “MAX” notches stamped on the side of the bat- tery.

  • Page 38: Installing The Battery

    “trickle” charger with a capacity of about 1/ 10th amp, attached. These chargers are very economically available from your Local aprilia Dealer, and will ensure that your battery always remains in tip top condition. If this cannot be done, charge the battery for about 30 minutes...
  • Page 39 Routine maintenance operations RS 50 To remove and clean the spark plug: WARNING Before carrying out the following operations, let the engine and the exhaust silencer cool down until they reach room temperature, in order to avoid burns. Remove the spark plug cap (1). Using compressed air, blow all the dirt away from the base of the spark plug.

  • Page 40: Air Cleaner

    Routine maintenance operations RS 50 AIR CLEANER WARNING Do not use gasoline or flammable solvents to wash the air cleaner, in order to avoid fire or explosion. Read carefully (MAINTENANCE). Check the condition of the air cleaner and clean it monthly or every 4,000 km (2,500 mi) depending on the conditions in which the motorcycle is used.

  • Page 41: Adjusting The Throttle Control

    Routine maintenance operations RS 50 ADJUSTING THE THROTTLE CONTROL Read carefully (SERVICING SCHEDULE). WARNING If the throttle sticks open, you will lose control of your motorcycle and a serious accident could result. If any fastener in the throttle system becomes loose, likewise you will lose control of your motorcycle.

  • Page 42: Carburetor Controls

    Routine maintenance operations RS 50 CARBURETOR CONTROLS COLD START LEVER The cold start lever (1) is located on the right side of the carburetor. It can be reached from above through the opening between the fairing and the frame. To operate the cold start lever, push the lever down- ward.
  • Page 43 Routine maintenance operations RS 50 CAUTION Danger of falling or turning over. As soon as the motorcycle is stood up, i.e. moved from the park position to the riding position, the stand retracts automatically. Keep the motorcycle in the vertical position with both wheels on the ground.

  • Page 44: Changing The Gearbox Oil

    Routine maintenance operations RS 50 CHANGING THE GEARBOX OIL Read carefully (GEARBOX OIL) and (SERVICING SCHEDULE). Check the gearbox oil level every 4,000 km (2,500 miles), change the oil after the first 500 km (312 miles) and then every 8,000 km (5,000 miles).
  • Page 45 Routine maintenance operations RS 50 Keep the motorcycle in a vertical position with the two wheels on the ground. Position a container (1) of capacity greater than 900 (30 US fl oz) under the drain plug (2). Unscrew and remove the drain plug (2).

  • Page 46: Stroke Oil Tank

    Routine maintenance operations RS 50 2 STROKE OIL TANK Top up the 2 stroke oil tank every 500 km (312 mi). The motorcycle is provided with a separate mixer that ensures the mixing of petrol and oil for the engine lubrication (LUBRICANT CHART).

  • Page 47: Coolant

    Routine maintenance operations RS 50 Remove the two screws (1) shown in the figure and take off the oil pump cover. Get a container of capacity greater than 2 l (1.1 gal). Remove the clamp (2) then detach the oil inlet tube (3), allowing all the oil to flow out of the tank into the container.
  • Page 48 Routine maintenance operations RS 50 WARNING Coolant is poisonous! Do not ingest coolant under any circumstance. Should you get coolant in your mouth, rinse with cool water and immediately seek medical atten- tion. Coolant is also very dangerous to your skin and eyes.
  • Page 49 Routine maintenance operations RS 50 CHECKING AND TOPPING UP WARNING Never remove the cap (1) when the engine is even warm, since the coolant is under high pressure and is very hot. If it splashes out and contacts your skin or clothing, it will cause severe burns.
  • Page 50 Routine maintenance operations RS 50 CHANGING THE COOLANT Read carefully (PRECAUTIONS AND GENERAL INFORMATION) and (COOLANT). Change the coolant every two years. Remove the right-hand side fairing (REMOVING THE SIDE FAIRINGS). Place a container under the drain plug (1) to collect the fluid (capacity greater than 1 l / 0.26 gal).

  • Page 51: Checking And Topping Up The Brake Fluid

    Routine maintenance operations RS 50 CHECKING AND TOPPING UP THE BRAKE FLUID NOTE This motorcycle is equipped with front and rear disc brakes with separate hydraulic systems. The following information may refer to just one braking system but should be observed with regard to both brakes.

  • Page 52: Front Brake

    Routine maintenance operations RS 50 CAUTION This motorcycle has front and rear hydraulic disc brakes. As the friction pads wear down, the fluid level de- creases to compensate automatically for the wear. The front brake fluid reservoir is situated on the right handlebar, next to the front brake lever attachment.
  • Page 53 Routine maintenance operations RS 50 WARNING Do not go over the “MAX” level when topping up. Fill to the “MAX” level only when new pads are fitted. The fluid level decreases gradually as the pads wear down. Do not fill to the “MAX” level with worn pads, as the fluid will spill out when the brake pads are replaced with new ones.

  • Page 54: Rear Brake

    Routine maintenance operations RS 50 REAR BRAKE CHECKING THE SYSTEM NOTE Carry out these checks only on a firm, flat surface such as a concrete garage floor. WARNING The side stand retracts automatically when the motorcycle is picked up from its leaned over position on the stand.

  • Page 55: Changing The Front Brake Fluid

    Routine maintenance operations RS 50 WARNING Fill to the “MAX” level only when new pads are fitted. The fluid level decreases gradually as the pads wear down. Do not fill to the “MAX” level with worn pads, as the fluid will spill out when the brake pads are replaced with new ones.

  • Page 56: Changing The Rear Brake Fluid

    Routine maintenance operations RS 50 Keep checking the fluid as it flows out of the reservoir (2), and tighten up the bleed valve (1) before the reservoir empties. Top up the reservoir (2) see (CHECKING AND TOP- PING UP THE BRAKE FLUID).

  • Page 57: Bleeding The Brake Circuits

    Routine maintenance operations RS 50 Keep checking the fluid as it flows out of the reservoir (2), and tighten up the bleed valve (1) before the reservoir empties. Top up the reservoir (2) see (CHECKING AND TOP- PING UP THE BRAKE FLUID).
  • Page 58 Routine maintenance operations RS 50 CAUTION Given the potential danger to the motorcycle and rider, it is absolutely essential to bleed the air from the hydraulic circuit after refitting the brakes and setting up the system for normal use condi- tions.

  • Page 59: Adjusting The Rear Brake

    Routine maintenance operations RS 50 ADJUSTING THE REAR BRAKE The brake pedal is adjusted to fit most riders during manufacture. If you wish to adjust the brake pedal: Position the motorcycle on the stand. Loosen the lock nut (1). Unscrew the brake adjusting bolt (2) completely.

  • Page 60: Adjusting The Clutch

    Routine maintenance operations RS 50 ADJUSTING THE CLUTCH The clutch needs adjusting when the engine cuts out, or when the motorcycle tends to move forward when it is in gear with the clutch lever engaged, or when the clutch “slips”, causing a lag in the acceleration in relation to the engine speed.

  • Page 61: Steering

    Routine maintenance operations RS 50 STEERING Read carefully (PRECAUTIONS AND GENERAL INFORMATION). To improve the handling, the steering has been fitted with antifriction bearings. The steering must be set correctly to ensure that the handlebar turns smoothly and steers the bike safely.

  • Page 62: Drive Chain

    Routine maintenance operations RS 50 Reposition the top plate (5), fitting it in correctly. Position the washer (2) on the sleeve then screw in and tighten up the sleeve cap (1). Torque setting for sleeve cap (1): 80 Nm (8.0 kgm) [59 Ft-lb].
  • Page 63 Routine maintenance operations RS 50 WARNING To inspect the condition of the chain, grasp the chain where it goes around the sprocket and try to pull it away from the sprocket. If you can move it more than one-eighth of an inch away from the sprocket, the chain is worn out and the chain and both front and rear sprockets must be replaced.
  • Page 64 Routine maintenance operations RS 50 ADJUSTMENT NOTE To adjust the chain it is necessary to use the appropriate rear support stand To adjust the chain tension: Position the motorcycle on the appropriate rear support stand , see (POSITIONING THE MOTOR- CYCLE ON THE REAR SUPPORT STAND Loosen the nut (1) to several turns.

  • Page 65: Routine Maintenance And Servicing Operations

    Routine maintenance operations RS 50 CLEANING AND LUBRICATION CAUTION Carry out the adjustment, lubrication, cleaning and change of the chain with great care. Lubricate the chain every 500 km (312 mi) or when- ever it appears dry. Use a proprietary chain lubricant or SAE 80W- 90 oil.
  • Page 66 Routine maintenance operations RS 50 WARNING Do not use the motorcycle if the tire wear indicators signal that a change is necessary. Some types of tires approved for this motorcycle are provided with wear indicators. There are several kinds of wear indicators.

  • Page 67: Fuel Lines

    Routine maintenance operations RS 50 WARNING New tires are often covered with a slippery mold release compound. Scrub the tires in by riding slowly and making numerous turns for the first few miles. Do not use any kind of tire dressing or other liquid on your tires.

  • Page 68: Stroke Oil Pipes/Hoses

    Routine maintenance operations RS 50 2 STROKE OIL PIPES/HOSES Check the state of the 2 stroke oil pipes/hoses (2) every 4,000 km (2,500 miles) or 8 months. Renew them every 4 years. Change the 2 stroke oil pipes/hoses if there are any signs of wear, scraping, etc.

  • Page 69: Fasteners

    Routine maintenance operations RS 50 FASTENERS Check, tightening when necessary, after the first 1,000 km (625 miles) and then every 7,500 km (4,687 miles) or 8 months. WARNING The fasteners listed in the table below must be tightened to the specified torque settings, using a torque wrench and, where indicated, LOCTITE ®...
  • Page 70 Routine maintenance operations RS 50 REAR SUSPENSION Description Qty. Screw/nut Nm (Ft-lb) Code Shock absorber to swing arm Allen screw M10x60 48 (35.4) 8150049 Shock absorber to pillar Allen screw M10x60 48 (35.4) 8150049 ENGINE Description Qty. Screw/nut Nm (Ft-lb)
  • Page 71 Routine maintenance operations RS 50 REAR BRAKE Description Qty. Screw/nut Nm (Ft-lb) Code Rear brake lever pin Dwg.5058 12 (8.8) 8121149 Rear brake master cylinder hex fl. M6x20 10 (7.4) 8152279 Brake lever adjuster hex fl. M5x16 5 (3.7) 8152273 Rear brake caliper hex fl.
  • Page 72 Routine maintenance operations RS 50 BODY Description Qty. Screw/nut Nm (Ft-lb) Kgm Code Reflector to front mudguard Nut M4 3 (2.2) 8150204 Front mudguard to stiffener plate hex fl. M6x16 7 (5.2) 8152278 Front mudguard to fork socket screw M5x12 5 (3.7)
  • Page 73 Routine maintenance operations RS 50 NOTES 2-44 ch. 2 Release 00 2001-03...
  • Page 74 Engine RS 50 Engine ch. 3 Release 00 2001-03...

  • Page 75: Engine Components That Can Be Removed Without Removing The Engine From The Frame

    Engine RS 50 ENGINE COMPONENTS THAT CAN BE REMOVED WITHOUT REMOVING THE ENGINE FROM THE FRAME Read carefully (PRECAUTIONS AND GENERAL INFORMATION). The parts listed below can be removed and refitted without removing the engine from the frame. WARNING The procedures in this chapter are described in a series of ordered steps.

  • Page 76: Removing The Complete Engine From The Frame

    Engine RS 50 REMOVING THE COMPLETE ENGINE FROM THE FRAME Read carefully (PRECAUTIONS AND GENERAL INFORMATION). WARNING Removing the engine is a particularly complex task. Study the motorcycle carefully before pro- ceeding. The procedures in this chapter are described in a series of ordered steps.
  • Page 77 Engine RS 50 Unscrew the ring nut (1) and remove the tachometer cable (2). Slide the boot (3) back. Loosen the nut (4) by screwing it counterclockwise. Turn in the adjustor (5) to slacken the clutch cable. Push the clutch lever (6) on the engine and discon- nect the clutch cable (7).
  • Page 78 Engine RS 50 Disconnect the oil pump control cable (10) and with- draw the cable from the wire guide (11). After withdrawing the oil line grommet, loosen and slide back the clamp (12) and withdraw the oil inlet tube (13).
  • Page 79 Engine RS 50 WARNING Remove all the clamps all the way along the cables and hoses. Prepare the same number of new clamps for refitting the cables and hoses. Plug all the openings in the engine, tubes and hoses to prevent foreign bodies from getting in the way.
  • Page 80 Engine RS 50 Unscrew and remove the 2 screws (36) and unscrew the screw that holds the bracket on the back of the starter motor. Remove the starter motor (37). Remove the engine cradle (38) (REMOVING THE ENGINE CRADLE). Prepare a hoist and straps for lifting.
  • Page 81 Engine RS 50 Remove the two engine mounting bolts from the frame (39), and remove the washers and self-locking nuts from the opposite side. CAUTION The engine is now free and not fastened at any point. Handle it with care; be careful about your fingers and limbs.
  • Page 82 Fuel supply system RS 50 Fuel supply system ch. 4 Release 00 2001-03...

  • Page 83: Chapter 4 Fuel Tank

    Fuel supply system RS 50 FUEL TANK The fuel tank is equipped with a filler cap, and a fuel valve. The valve, as shown in the figure, has three positions (OFF, ON and RES), which may be selected with the valve lever.

  • Page 84: Maintenance

    Fuel supply system RS 50 Read carefully (PRECAUTIONS AND GENERAL INFORMATION) and (FUEL). MAINTENANCE To service the tank, it has to be removed (REMOVING THE TANK) and washed completely. CHECKING THE FUEL FEED Check the fuel pipes/hoses every 4,000 Km (2,500 miles) or 8 months.

  • Page 85: Removing The Fuel Valve

    Fuel supply system RS 50 REMOVING THE FUEL VALVE Raise up the tank (RAISING THE FUEL TANK). Remove the screws (1) and extract the complete fuel valve (2). Reposition the petrol cock (2) under the tank and screw in the two screws (1).
  • Page 86 Fuel supply system RS 50 DESCRIPTION 12)Fuel filter 1)Choke 2)Throttle valve 13)Choke control shaft 14)Needle 3)Main jet 15)Float pin 4)Float 16)Clamp screw 5)Deflector tube kit 17)Float chamber 6)Gaskets 18)Float chamber retainer screw 7)Valve cover 8)Throttle valve return spring 19)Adapter 9)Connection fitting retainer screw...

  • Page 87: Removing The 2 Stroke Oil Tank

    Fuel supply system RS 50 REMOVING THE 2 STROKE OIL TANK Read carefully (PRECAUTIONS AND GENERAL INFORMATION). Remove the rider and passenger saddle (REMOVING THE RIDER AND PASSENGER SADDLE). Remove the fuel tank (REMOVING THE FUEL TANK). Remove the rear fairing (REMOVING THE REAR FAIRING).
  • Page 88 Fuel supply system RS 50 Remove the clamp (3) and disconnect the tube (4) that delivers oil to the pump. To remove the two stroke oil tank (5), rotate it towards the rear of the frame as you lift it out.
  • Page 89 Fuel supply system RS 50 NOTES ch. 4 Release 00 2001-03...
  • Page 90 Cooling system RS 50 Cooling system ch. 5 Release 00 2001-03...

  • Page 91: Removing The Radiator

    Cooling system RS 50 REMOVING THE RADIATOR Read carefully (PRECAUTIONS AND GENERAL INFORMATION) and (COOLANT). Remove the r.h side fairing (REMOVING THE SIDE FAIRINGS). Remove the saddle cowl (REMOVING THE SADDLE COWL). Drain all the coolant from the cooling system (CHANGING THE COOLANT).

  • Page 92: Removing The Filler Cap

    Cooling system RS 50 WARNING Plug the ends of the hoses, to prevent foreign bodies from getting into them. NOTE Replace the rubber pads (9) if worn. CAUTION Any foreign material, dirt etc. that is stuck to the radiator fins must be removed with a blast of compressed air.
  • Page 93 Cooling system RS 50 NOTES ch. 5 Release 00 2001-03...
  • Page 94 Electrical system RS 50 Electrical system ch. 6 Release 00 2001-03...

  • Page 95: Chapter 6 Introduction

    Electrical system RS 50 INTRODUCTION Read carefully (PRECAUTIONS AND GENERAL INFORMATIONS) and (BATTERY). The information below will be useful when con- sulting this section. NOTE The numbering in the specific wiring diagrams corresponds to that in the main wiring diagram.

  • Page 96: Main Wiring Diagram

    Electrical system RS 50 MAIN WIRING DIAGRAM MAIN WIRING DIAGRAM KEY 21) Left turn signal warning light Generator 22) High beam warning light Ignition coil Voltage regulator 23) Low beam warning light 24) Two stroke oil reserve warning light Rectifier...

  • Page 97: Location Of Components

    Electrical system RS 50 LOCATION OF COMPONENTS 21 23 25 26 Generator 21) Left direction indicators warning light Ignition coil 22) High beam warning light Voltage regulator 23) Low beam warning light Rectifier 24) Two stroke oil reserve warning light...

  • Page 98: Ignition Circuit

    Electrical system RS 50 IGNITION CIRCUIT Location of components see (LOCATION OF COM- PONENTS). WIRING DIAGRAM Bi/R Bi/R Generator Coil 35) Spark plug 15) Ignition switch 16) Right high/low beam selector TECHNICAL DATA Spark plug ..........NGK R BR9ES Spark gap ...... 0.6 ± 0.7 mm (0.02 ± 0.03 in) Spark advance ..........
  • Page 99 Electrical system RS 50 If the fault persists: Check the H.T. lead. Check the spark plug cap. Check the magneto flywheel (CHECKING THE MAGNETO FLYWHEEL). Replace the coil with one that you know is good. If the fault ceases: Check the ignition switch (CHECKING THE IGNITION SWITCH).

  • Page 100: Recharge And General Power Supply Circuit

    Electrical system RS 50 RECHARGE AND GENERAL POWER SUPPLY CIRCUIT Location of components see (LOCATION OF COM- PONENTS). WIRING DIAGRAM Lights D.C. utilities Generator Voltage regulator Rectifier Battery 15) Ignition switch TECHNICAL DATA Generator ............ 105 W a.c. a 6000 rpm Voltage regulator ..........
  • Page 101 Electrical system RS 50 TROUBLESHOOTING A. BATTERY DOESN’T STAY CHARGED Check the fuse, replacing it if necessary. Replace the rectifier. Check the wiring connections on the regulator, fly- wheel, battery and fuse. Check the battery (CHECKING THE BATTERY). Check the generator (CHECKING THE GENERA- TOR).

  • Page 102: Starter Circuit

    Electrical system RS 50 CHECK DATA CHECKING THE GENERATOR Disconnect the yellow wire from the regulator. Start the engine and run it at 6000 rpm. Using a tester in A.C. voltmeter mode, test the voltage between: generator yellow and ground wires = reading greater than 35 V.
  • Page 103 Electrical system RS 50 TECHNICAL DATA Starter motor ........... 12 V - 150 W Brush wear limit ........0.9 mm (0.03 in) Starter relay ..........12 V - 70 A Battery ............12 V - 4 Ah TROUBLESHOOTING A. STARTER MOTOR DOESN’T TURN OR TURNS VERY SLOWLY Check the battery (CHECKING THE BATTERY).
  • Page 104 Electrical system RS 50 CHECK DATA CHECKING THE STARTER RELAY Disconnect all the wires from the relay. Using a multimeter with the scale set to ohms, test the continuity between terminals 30 and 87. Exact value: infinity. Apply voltage to terminals 85 and 86 with a 12 V battery.

  • Page 105: Sensor Circuit

    Electrical system RS 50 SENSOR CIRCUIT Location of components see (LOCATION OF COM- PONENTS). WIRING DIAGRAM Positive key-controlled Bi/N Oil reserve sensor Water temperature thermistor 10) Neutral gear sensor 19) Water temperature gauge 24) Oil reserve warning light 25) Neutral gear warning light...

  • Page 106: Direction Indicators Circuit

    Electrical system RS 50 B. STAYS LIT WHEN OIL LEVEL IS SUFFICIENT Check the wiring connections. Check the oil level sensor (CHECKING THE OIL LEVEL SENSOR). CHECK DATA CHECKING THE OIL LEVEL SENSOR Disconnect the sensor wires and remove the sensor from the tank.
  • Page 107 Electrical system RS 50 TECHNICAL DATA Direction indicator bulbs .......... 12 V - 10 W B.A. 15 S Flasher ............12 V - 22 W All-glass type direction indicator warning light bulbs ....12 V - 2 W - W2.1x9.5d TROUBLESHOOTING A.

  • Page 108: Horn Circuit

    Electrical system RS 50 HORN CIRCUIT Location of components see (LOCATION OF COM- PONENTS). WIRING DIAGRAM Positive key-controlled 17) Horn button 31) Horn TECHNICAL DATA Horn ............... 12 V c.c. TROUBLESHOOTING A. DOESN’T SOUND, OR SOUNDS BADLY Check the battery (CHECKING THE BATTERY).
  • Page 109 Electrical system RS 50 B. SOUNDS CONTINUOUSLY Check the wiring connections. Check the horn button (CHECKING THE HORN BUTTON). CHECK DATA CHECKING THE HORN Disconnect the horn and apply voltage to it directly with a 12 V battery. Adjust with the adjuster, if necessary.

  • Page 110: Braking Lights Circuit

    Electrical system RS 50 BRAKING LIGHTS CIRCUIT Location of components see (LOCATION OF COM- PONENTS). WIRING DIAGRAM Positive key-controlled Brake light rear switch 13) Taillight (brake light bulb) 36) Brake light front switch TECHNICAL DATA Brake lights bulb ............12 V - 21 W TROUBLESHOOTING A.
  • Page 111 Electrical system RS 50 B. BRAKE LIGHT DOESN’T SWITCH ON Check the bulb and bulb holder. Check the wiring connections. Check the general power supply circuit. Check the brake light front switch (CHECKING THE BRAKE LIGHT FRONT AND REAR SWITCH).

  • Page 112: Light Circuit

    Electrical system RS 50 LIGHT CIRCUIT Location of components see (LOCATION OF COM- PONENTS). WIRING DIAGRAM From flywheel PASS Regulator 11) Low beam light 13) Rear parking light 16) Right high/low beam selector 17) Left high/low beam selector 20) Dashboard light...

  • Page 113: Light Circuit

    Electrical system RS 50 LIGHT CIRCUIT Location of components see (LOCATION OF COM- PONENTS). WIRING DIAGRAM From flywheel PASS Regulator 11) Low beam light 13) Rear parking light 16) Right high/low beam selector 17) Left high/low beam selector 20) Dashboard light...

  • Page 114: Electrical System Troubleshooting

    Electrical system RS 50 TROUBLESHOOTING A. A LIGHT DOESN’T WORK Check the bulb. Check for voltage on the bulb holder terminals. Check the wiring connections. B. NONE OF THE LIGHTS WORK Check the high/low beam selectors. Check the voltage regulator (CHECKING THE VOLT- AGE REGULATOR).
  • Page 115 Electrical system RS 50 WATER TEMPERATURE SENSOR TROUBLESHOOTING A. TEMPERATURE READING TOO LOW Check the connections. Check that the green/red wire on the sensor is sup- plied with power. Check the coolant thermistor (1). Check the coolant temperature gauge (2).

  • Page 116: Electrical Connectors

    Electrical system RS 50 As illustrated in the figure, connect a multimeter (D) with the scale set to ohms to the thermistor (1). Immerse the thermistor in a receptacle (F) containing coolant. Immerse a thermometer (E) with a range of 0° ±150°C (32°...

  • Page 117: Bulbs

    Electrical system RS 50 BULBS Read carefully (MAINTENANCE). CAUTION Risk of fire. Keep fuel and other flammable sub- stances away from the electrical components. Before changing a bulb, turn the ignition switch to the “ ” (OFF) position and wait a few minutes so that the bulb cools down.

  • Page 118: Changing High Beam Bulb

    Electrical system RS 50 CHANGING HIGH BEAM BULB NOTE Remove the bulb sockets one by one in such a way as to avoid replacing them incorrectly during reassembly. If the bulb sockets must all be removed at the same time, take great care to reassemble them in the proper position.

  • Page 119: Changing The Front And Rear Turn Signal Bulbs

    Electrical system RS 50 CHANGING THE FRONT AND REAR TURN SIGNAL BULBS Read carefully (BULBS). NOTE Before changing a bulb, check the fuse, see (CHANGING FUSES). Position the motorcycle on the stand. Unscrew and remove the screw (1). NOTE While removing the lens, use extra care to be sure that you do not break the key.

  • Page 120: Adjusting The Headlight Beam Vertically

    Electrical system RS 50 NOTE Ensure that the orientation of your replace- ment bulb is identical to that of the original bulb. Do not try to force the bulb (7), it will fit easily if it is properly oriented. ADJUSTING THE...
  • Page 121 Electrical system RS 50 To adjust the beam: Remove the front part of the fairing, see (REMOVING THE FRONT PART OF THE FAIRING). Unscrew and remove the screw (1). Unscrew and remove the screws (2). CAUTION Handle with care. Take care not to damage the electric wires.

  • Page 122: Change Fuses

    NOTE If a fuse blows frequently, there probably is a short circuit or an overload in the electrical system. If this occurs, take the motorcycle to your Local aprilia Dealer. 6-29 ch. 6 Release 00...
  • Page 123 Electrical system RS 50 If an electric component does not work or works irregularly, or if the motorcycle fails to start, it is necessary to check the fuse (1). To check the fuse: Turn the ignition switch (2) in the “ ” (OFF) position.

  • Page 124: Checking The Switches

    Electrical system RS 50 CHECKING THE SWITCHES Read carefully (SERVICING SCHEDULE). The motorcycle is equipped with three switches: Stoplight switch on the rear brake pedal (1); Stoplight switch on the front brake lever (2); Safety switch on the side stand (3).
  • Page 125 Electrical system RS 50 NOTES 6-32 ch. 6 Release 00 2001-03...
  • Page 126 Body work RS 50 Body work ch. 7 Release 00 2001-03...

  • Page 127: Applying The Transfers

    Body work RS 50 APPLYING THE TRANSFERS When removing parts of the frame: CAUTION Handle plastic and painted parts carefully so as not to scratch or damage them. Perform the work with the utmost care. Do not damage the tabs and/or the slots into which they are inserted.
  • Page 128 Body work RS 50 NOTE The application tape (1), if present, must be removed 20-30 minutes after the application of the transfer. The tape is used in the application of logos and letters, making it easier to position them correctly on the surface and helping the glue to set more firmly.

  • Page 129: Removing The Rider Saddle

    Body work RS 50 REMOVING THE RIDER SADDLE Read carefully (SERVICING SCHEDULE). Position the motorcycle on the stand. Insert the key (1) in the lock (2). Rotate the key (1) clockwise. Raise and remove the saddle (3). Remove the flap (4).

  • Page 130: Removing The Side Fairings

    Body work RS 50 REMOVING THE SIDE FAIRINGS Read carefully (SERVICING SCHEDULE). WARNING Before carrying out the following operations, let the engine and the exhaust silencer cool down until they reach room temperature, in order to avoid burns. Position the motorcycle on the stand.

  • Page 131: Removing The Fuel Tank

    Body work RS 50 REMOVING THE FUEL TANK Read carefully (FUEL) and (SERVICING SCHED- ULE). WARNING Risk of fire. Wait until the engine and the exhaust silencer have completely cooled down. Fuel vapors are poisonous. Make sure that the room in which you are working is properly ventilated.

  • Page 132: Emptying The Fuel Tank

    Body work RS 50 Replace the tank in its working position. Loosen and remove the nut (9) that holds the bolt (10). After removing the nut (9), withdraw the bolt (10) from its hole, where it fixes the tank to the frame.

  • Page 133: Removing The Air Box

    Body work RS 50 REMOVING THE AIR BOX Read carefully (SERVICING SCHEDULE). Remove the fuel tank (REMOVING THE FUEL TANK). Unscrew the screw (1) to loosen the clamp (2) on the intake hose leading to the carburetor. Unscrew and remove the screws (3) that secure the air box (4) to the frame.

  • Page 134: Removing The Left Handlebar Handgrip

    Body work RS 50 REMOVING THE LEFT HANDLEBAR HANDGRIP Read carefully (PRECAUTIONS AND GENERAL INFORMATION). Position the motorcycle on the stand. Switch the ignition key to the “ “ position. Hold the counterweight (1) while loosening and removing the screw (2).

  • Page 135: Removing The Clutch Control

    Body work RS 50 REMOVING THE CLUTCH CONTROL Read carefully (PRECAUTIONS AND GENERAL INFORMATION). Position the motorcycle on the stand. Switch the ignition key to the “ “ position. Slide back the boot (1). Loosen the nut (2) by twisting it until it butts up against the adjustor (3).

  • Page 136: Removing The Throttle Control

    Body work RS 50 REMOVING THE THROTTLE CONTROL Read carefully (PRECAUTIONS AND GENERAL INFORMATION). Position the motorcycle on the stand. Switch the ignition key to the “ “ position. Hold the counterweight (1) while loosening and removing the screw (2).

  • Page 137: Removing The Right Handlebar Electrical Controls

    Body work RS 50 REMOVING THE RIGHT HANDLEBAR ELECTRICAL CONTROLS Read carefully (PRECAUTIONS AND GENERAL INFORMATION). Position the motorcycle on the stand. Switch the ignition key to the “ “ position. The only operation required is to disconnect the throttle cable (1) from the block.

  • Page 138: Removing The Front Brake Control

    Body work RS 50 REMOVING THE FRONT BRAKE CONTROL Read carefully (PRECAUTIONS AND GENERAL INFORMATION). Position the motorcycle on the stand. Switch the ignition key to the “ “ position. Unscrew and remove the 2 screws (1) that secure the front brake control (2).

  • Page 139: Removing The Right Handlebar

    Body work RS 50 REMOVING THE RIGHT HANDLEBAR Read carefully (PRECAUTIONS AND GENERAL INFORMATION). Position the motorcycle on the stand. Loosen and remove the screw (1). Remove the washer. Withdraw the right handlebar (2) with all its controls. NOTE If necessary, remove the front brake control...

  • Page 140: Removing The Ignition Switch/Steering Lock

    Body work RS 50 REMOVING THE IGNITION SWITCH/ STEERING LOCK Read carefully (PRECAUTIONS AND GENERAL INFORMATION). Position the motorcycle on the stand. Switch the ignition key to the “ “ position. Remove the right and left handlebars (REMOVING THE RIGHT HANDLEBAR, REMOVING THE LEFT HANDLEBAR).

  • Page 141: Removing The Front Fairing

    Body work RS 50 NOTE Repeat the same steps to remove the other rear view mirror. NOTE After refitting, set the rear view mirrors cor- rectly and tighten up the nuts to make sure they are securely fixed. REMOVING THE WINDSHIELD Position the motorcycle on the stand.

  • Page 142: Removing The Headlight

    Body work RS 50 Move the front fairing (8) slightly forward. Disconnect the headlight electrical connector (9). NOTE When refitting, make sure the connector (9) is plugged in properly. Handle plastic and painted parts carefully, to avoid scraping or damaging them.
  • Page 143 Body work RS 50 NOTE Make sure the electrical connections are correct when refitting. Loosen and remove the 3 self-locking nuts (7) and washers. Torque wrench setting for nut (7): 10 Nm (1 kgm) [7.4 Ft-lb]. Remove the dashboard (6).

  • Page 144: Removing The Front Mudguard

    Body work RS 50 REMOVING THE FRONT MUDGUARD Read carefully (PRECAUTIONS AND GENERAL INFORMATION). Position the motorcycle on the stand. Loosen and remove the 4 screws (1). Torque setting for screws (1): 7 Nm (0.7 kgm) [5.2 Ft-lb]. Remove the self-locking nuts (2).

  • Page 145: Removing The Lower Fairing

    Body work RS 50 REMOVING THE LOWER FAIRING Read carefully (PRECAUTIONS AND GENERAL INFORMATION). WARNING Handle plastic and painted parts carefully, without scraping or damaging them. Position the motorcycle on the rear stand WARNING Wait until the engine and exhaust muffler have cooled down completely.

  • Page 146: Removing The Rear Fairing

    Body work RS 50 REMOVING THE REAR FAIRING Read carefully (PRECAUTIONS AND GENERAL INFORMATION). WARNING Wait until the engine and exhaust muffler cool down completely. Remove the rider saddle (REMOVING THE RIDER SADDLE). Loosen and remove the nut (1) that attaches the passenger saddle to the rear fairing.

  • Page 147: Removing The Rear Light

    Body work RS 50 REMOVING THE REAR LIGHT Read carefully (PRECAUTIONS AND GENERAL INFORMATION). Switch the ignition key to the “ “ position. Carry out the procedure for changing the rear light bulb (CHANGING THE REAR LIGHT BULB). Withdraw and slightly loosen the reflector (1).

  • Page 148: Removing The Pillar Cover

    Body work RS 50 REMOVING THE PILLAR COVER Read carefully (PRECAUTIONS AND GENERAL INFORMATION). Remove the rider saddle (REMOVING THE RIDER SADDLE). Raise up the tank (RAISING THE FUEL TANK). Loosen and remove the 4 screws (1). WARNING Handle plastic and painted parts carefully, without scraping or damaging them.

  • Page 149: Removing The Rear Mudguard

    Body work RS 50 REMOVING THE REAR MUDGUARD Read carefully (PRECAUTIONS AND GENERAL INFORMATION). Position the motorcycle on the stand. WARNING Wait until the engine and exhaust muffler cool down completely. Loosen and remove the 2 screws (1). Torque setting for screws (1): 5 Nm (0.5 kgm) [3.7 Ft-lb].

  • Page 150: Removing The Rear Footrests

    Body work RS 50 Loosen and remove the screws (4) under the pillar cover. Torque setting for screws (4): 24 Nm (2.4 kgm) [17.7 Ft-lb]. Remove the footrest support (5) complete with foot- rest. If necessary, remove the footrest (5) (REMOVING THE REAR FOOTRESTS).

  • Page 151: Removing The Front Footrest Support (Right Side)

    Body work RS 50 Remove the shift lever (1) (REMOVING THE SHIFT LEVER). Loosen and remove the screws (2). Torque setting for screws (2): 25 Nm (2.5 kgm) [18.4 Ft-lb]. Remove the front footrest support (3) complete with footrest (4).

  • Page 152: Removing The Front Footrest

    Body work RS 50 REMOVING THE FRONT FOOTREST Read carefully (PRECAUTIONS AND GENERAL INFORMATION). Position the motorcycle on the stand. CAUTION Wait until the engine and exhaust muffler cool down completely. Remove the retainer ring (1). Withdraw the pin (2).

  • Page 153: Removing The Brake Pedal

    Body work RS 50 REMOVING THE BRAKE PEDAL Read carefully (PRECAUTIONS AND GENERAL INFORMATION). Position the motorcycle on the stand. Loosen and remove the nut (1). Torque setting for nut (1): 5 Nm (0.5 kgm) [3.7 Ft-lb]. Release the spring (2).
  • Page 154 Body work RS 50 Loosen and remove the screw (9). Torque setting for screw (9): 12 Nm (1.2 kgm) [8.8 Ft-lb]. Take off the washer (10). The exhaust pipe must be supported during this operation. Loosen and remove the screw (11).

  • Page 155: Removing The Muffler

    Body work RS 50 REMOVING THE MUFFLER Read carefully (PRECAUTIONS AND GENERAL INFORMATION) and (SERVICING SCHEDULE). The exhaust pipe and muffler must be cleaned every 4,000 km (2,500 miles). WARNING It is against the law to use the motorcycle without an exhaust pipe and/or muffler.

  • Page 156: Cleaning The Exhaust Pipe And Muffler

    Body work RS 50 CLEANING THE EXHAUST PIPE AND MUFFLER Read carefully (PRECAUTIONS AND GENERAL INFORMATION) and (SERVICING SCHEDULE). Remove the exhaust muffler (REMOVING THE MUFFLER). NOTE Get a flexible tube brush (1) of suitable diameter. CAUTION Do not use any other tool except the tube brush.

  • Page 157: Removing The Side Stand

    Body work RS 50 REMOVING THE SIDE STAND Read carefully (PRECAUTIONS AND GENERAL INFORMATION). Position the motorcycle on the rear stand Rear stand: 8705021. WARNING The sidestand is equipped with a very powerful spring. If you should get a finger wedged between the spring and the stand, or between the spring and the frame, you will be seriously injured.

  • Page 158: Removing The Chain Guide

    Body work RS 50 REMOVING THE CHAIN GUIDE Read carefully (PRECAUTIONS AND GENERAL INFORMATION). Remove the swing arm (REMOVING THE SWING ARM). Loosen and remove the screw (1). Torque setting for screw (1): 3 Nm (0.3 kgm) [2.2 Ft-lb]. Remove the cap (2).
  • Page 159 Body work RS 50 Loosen and remove the screw (8). Torque setting for screw (8): 3 Nm (0.3 kgm) [2.2 Ft-lb]. Tape or wire the brake fluid reservoir (9) in a vertical position on the frame to prevent the brake fluid from spilling out.
  • Page 160 Body work RS 50 NOTE The following operation must be performed from the opposite side of the motorcycle. Loosen and remove the 2 screws (14) and (15). Torque setting for screw (14): 24 Nm (2.4 kgm) [17.7 Ft-lb]. Torque setting for screw (15): 47 Nm (4.7 kgm) [34.7 Ft-lb].

  • Page 161: Front Wheel

    Body work RS 50 FRONT WHEEL 1) Axle 2) Odometer drive cover 3) Odometer drive 4) Washer 5) Bearing 6) Internal spacer 7) External spacer 8) Washer 9) Nut 7-36 ch. 7 Release 00 2001-03...

  • Page 162: Removing The Complete Front Wheel

    Body work RS 50 REMOVING THE COMPLETE FRONT WHEEL Read carefully (SERVICING SCHEDULE). While disassembling and reassembling the wheel, pay extra care not to damage the brake lines, discs or pads. NOTE You must use the appropriate front and rear support stands to remove the front wheel.

  • Page 163: Disassembling The Front Wheel

    Body work RS 50 Prevent the axle (5) from rotating with an appropriate Allen wrench. Remove the nut (6) and washer (7). Wheel nut (6) tightening torque: 59 Ft-lb (8 kgm) [80 Nm]. Loosen the axle clamp screw (8), using the appropri- ate Allen wrench.
  • Page 164 Body work RS 50 WARNING When refitting the bearings, use a drift with the same diameter as the outside race of the bearings. Do not drive on the balls and/or the inner ring. Make sure the following parts are fitted together perfectly: the right bearing (1) against the hub;...

  • Page 165: Reassembly Front Wheel

    Body work RS 50 Using a dial gauge, check that the radial runout (A) and axial runout (B) on the rim (5) do not exceed the specified limits. Excessive runout is usually caused by worn or dam- aged bearings. If, after replacing the bearings, the runout is still not within the stated limit, replace the rim (5).
  • Page 166 Body work RS 50 CAUTION While reassembling the wheel, be careful not to damage the brake line, the disc and the pads. Install the brake caliper (10) over the disc and position it so that its fastening holes and the holes on the support are aligned.

  • Page 167: Front Brake

    Body work RS 50 FRONT BRAKE 1) Brake lever 2) Front brake master cylinder 3) Brake fluid reservoir 4) Brake light switch 5) Master cylinder-to-caliper brake line 6) Brake caliper 7) Bleeder screw 8) Brake pads 9) Brake disc 7-42 ch.

  • Page 168: Changing The Front Brake Pads

    Body work RS 50 CHANGING THE FRONT BRAKE PADS Read carefully (PRECAUTIONS AND GENERAL INFORMATION) and (CHECKING THE WEAR ON THE BRAKE PADS). Position the motorcycle on the stand. Using a hex wrench, loosen and remove the screws (1) that secure the pads to the front brake caliper.

  • Page 169: Removing The Front Brake Master Cylinder

    Body work RS 50 REMOVING THE FRONT BRAKE MASTER CYLINDER See (REMOVING THE FRONT BRAKE CONTROL). REMOVING THE BRAKE DISC Read carefully (PRECAUTIONS AND GENERAL INFORMATION). Remove the front wheel (REMOVING THE COM- PLETE FRONT WHEEL). NOTE It is helpful to use an impact wrench to loosen...

  • Page 170: Front Fork

    Body work RS 50 FRONT FORK 1) Circlip 12) Sliding bush 2) Tube plug 13) Slider 3) O-ring 14) Seal washer 4) Spring 15) Oil drain screw 5) Complete plunger 6) End bumper 7) Fork tube 8) Dust cover 9) Retainer ring...

  • Page 171: Removing The Front Fork

    Body work RS 50 REMOVING THE FRONT FORK Read carefully (PRECAUTIONS AND GENERAL INFORMATION). Remove the fairings (REMOVING THE SIDE FAIR- INGS). Remove the saddle cowl (REMOVING THE LOWER FAIRING). Remove the front wheel (REMOVE THE COMPLETE FRONT WHEEL). Remove the front mudguard (REMOVING THE FRONT MUDGUARD).

  • Page 172: Disassembling The Fork

    Body work RS 50 DISASSEMBLING THE FORK Read carefully (PRECAUTIONS AND GENERAL INFORMATION) and (FORK OIL). NOTE The right and left fork legs have the same internal components. The procedure described below refers to a single fork, but is applicable to both.
  • Page 173 Body work RS 50 NOTE Before completely removing the spring (5), hold it just out of the tube (6) for a few seconds so that part of the oil runs down into the tube. Remove the spring (5). Turn the fork upside down and pour the oil out into a container (7).
  • Page 174 Body work RS 50 NOTE The following operation requires the applica- tion of considerable force. Withdraw the fork tube (6) complete with plunger (12) end bumper (13). CAUTION Do not disassemble the plunger (3). Remove the dust cover (11) (see previous figure) from the tube (6).

  • Page 175: Checking The Components

    Body work RS 50 CHECKING THE COMPONENTS TUBE Check for scoring and/or scratches on the slide surface. Very slight scoring can be removed with emery cloth or 600 wet or dry paper, wetted with fire- proof solvent. Move the paper up and down the tube, do not place the tube in a lathe to polish it.

  • Page 176: Refitting The Fork

    Body work RS 50 WARNING Remove any impurities from the bushes, being careful not to scratch the surfaces. Replace the following parts with new ones: oil seal (4); dust seal (5); the 2 O-rings on the tube plug (6). REFITTING THE FORK Read carefully (PRECAUTIONS AND GENERAL INFORMATION).
  • Page 177 Body work RS 50 CAUTION Use a plastic-headed mallet (4) for the following operations. Using a drift of suitable diameter (5), fit the new oil seal into the slider (1), ensuring that it is fully seated by tapping lightly several times with a plastic hammer (4).
  • Page 178 Body work RS 50 With the tube fully extended, fit the dust cover (10) on to the slider (1) (see pervious figure). Hold the fork (11) in a vertical position. Pour fork oil (see LUBRICANT CHART) into the fork, until it reaches the correct level.

  • Page 179: Steering

    Body work RS 50 STEERING 1) Steering stem tube 2) Washer 3) Upper plate 4) Ball bearing 5) Ring nut 6) Retainer ring 7) Washer 8) Roller bearing 9) Washer 10) Lower plate with steering stem 7-54 ch. 7 Release 00...

  • Page 180: Removing The Steering

    Body work RS 50 REMOVING THE STEERING Read carefully (PRECAUTIONS AND GENERAL INFORMATION) and (STEERING). Position the motorcycle on the rear stand on a lift platform (POSITIONING THE MOTORCYCLE ON THE REAR STAND Remove the fairings (REMOVING THE SIDE FAIRINGS).

  • Page 181: Checking The Components

    Body work RS 50 Loosen and remove the adjustor ring nut (1). Remove the roller bearing (3) and the retainer ring (4) from the steering stem (2). Remove the ring seal (5) and washer (6). Using a bearing puller, remove the bearing (7) from its seat in the frame.

  • Page 182: Refitting The Steering

    Body work RS 50 REFITTING THE STEERING NOTE For reassembly, the motorcycle and front fork must be positioned as for disassembly. Follow the disassembly procedure in reverse. Apply a thin film of grease along the whole of the stem (1) and to the roller bearings (2).

  • Page 183: Rear Wheel

    Body work RS 50 REAR WHEEL 1) Nut 12) Rear sprocket 2) Washer 13) Chain guide 3) Chain guide 14) Washer 4) Spacer 15) Axle 5) Caliper mounting plate 6) Spacer 7) Brake disc 8) Bearings 9) Spacer 10) Complete wheel...
  • Page 184 Body work RS 50 REMOVING THE COMPLETE REAR WHEEL Read carefully (SERVICING SCHEDULE). WARNING Before proceeding, allow the engine and exhaust to cool down to ambient temperature, to avoid possible burns. While disassembling and reassembling the wheel, pay extra care not to damage the brake lines, discs or pads.

  • Page 185: Removing The Complete Rear Wheel

    Should you accidentally do this, take your motor- cycle to your Local aprilia Delear who will know how to repair this damage. DISASSEMBLING THE REAR WHEEL Read carefully (PRECAUTIONS AND GENERAL INFORMATION).

  • Page 186: Reassembly Rear Wheel

    Body work RS 50 REASSEMBLY REAR WHEEL Read carefully (SERVICING SCHEDULE). Apply a thin film of grease to the outer seals of the rear wheel hub. CAUTION The spacers have different diameters: do not mix them up and take care to position them correctly.
  • Page 187 Check the wheel centering. Have the tightening torques, centering and bal- ancing of the wheel checked by your Local aprilia Delear. These are critical safety operations, and failure to observe this warning could lead to an upset with subsequent serious injury or death.

  • Page 188: Rear Brake

    Body work RS 50 REAR BRAKE 1) Brake fluid reservoir 2) Reservoir-to-master cylinder brake fluid tube 3) Brake light switch 4) Brake master cylinder 5) Master cylinder-to-caliper brake fluid tube 6) Brake pedal 7) Brake disc 8) Bleed valve 9) Brake caliper...

  • Page 189: Changing The Rear Brake Pads

    Body work RS 50 CHANGING THE REAR BRAKE PADS Read carefully (PRECAUTIONS AND GENERAL INFORMATION) and (CHECKING THE WEAR ON THE BRAKE PADS). Position the motorcycle on the stand. Remove the brake caliper cover (1). NOTE Before withdrawing the pin (3), check the position of the safety spring (4);...

  • Page 190: Removing The Rear Brake Disc

    Body work RS 50 REMOVING THE REAR BRAKE DISC Read carefully (PRECAUTIONS AND GENERAL INFORMATION). Remove the rear wheel (REMOVING THE COM- PLETE REAR WHEEL). NOTE It is helpful to use an impact wrench to loosen the bolts (1), since they are locked in place using ®...

  • Page 191: Removing The Rear Suspension

    Body work RS 50 Loosen and move the tube clamp (4). Withdraw the tube (5) and remove the 2 screws (6). Torque setting for screws (6): 10 Nm (1.0 kgm) [7.4 Ft-lb]. Remove the master cylinder (7), taking it out from the front.

  • Page 192: Checking The Suspension Components

    Body work RS 50 Remove the 4 T-bushes (5) and withdraw the 2 silent- blocks (6). NOTE Wash all components with fire-proof solvent. Check the components (CHECKING THE SUSPEN- SION COMPONENTS). CHECKING THE SUSPENSION COMPONENTS WARNING Ensure that none of the components show any signs of bending, cracking, or denting.

  • Page 193: Removing The Drive Chain

    Body work RS 50 REMOVING THE DRIVE CHAIN Read carefully (SERVICE SCHEDULE) and (PRE- CAUTIONS AND GENERAL INFORMATION). Position the motorcycle on the rear stand (POSI- TIONING THE MOTORCYCLE ON THE REAR STAND). Rear stand: 8705021. WARNING Take extra care to ensure that your fingers are not caught between the chain and the rear sprocket.

  • Page 194: Removing The Swing Arm

    Body work RS 50 REMOVING THE SWING ARM Read carefully (PRECAUTIONS AND GENERAL INFORMATION). Remove the side fairings (REMOVING THE SIDE FAIRINGS). Remove the saddle cowl (REMOVING THE LOWER FAIRING). Remove the exhaust pipe, (REMOVING THE EX- HAUST PIPE AND MUFFLER).
  • Page 195 Body work RS 50 NOTE Use the special tool (swing arm pin adjust- ment socket wrench). Using the special socket wrench (6), loosen and remove the locking ring nut (7). Swing arm pin adjustment socket wrench: 8101945 WARNING Because of the weight of the rear part, the follow- ing operations require a second person.

  • Page 196: Disassembling The Swing Arm

    Body work RS 50 DISASSEMBLING THE SWING ARM Read carefully (PRECAUTIONS AND GENERAL INFORMATION). Remove the bushes (1). Remove the O-rings (2). WARNING When reassembling, use 2 new O-rings (2). Remove the internal spacer (3). Using a drift of suitable diameter, remove the internal bushes (4).

  • Page 197: Reassembling The Swing Arm

    Body work RS 50 REASSEMBLING THE SWING ARM Read carefully (PRECAUTIONS AND GENERAL INFORMATION). Install the internal spacer (3). Using an appropriate shoulder drift, install the internal bushings (2), fit to the O-ring seals (4) fit the two outer bushings (6) in the left side of the swinging arm, ensuring that it is driven fully home.
  • Page 198 Body work RS 50 Fully tighten the pin (1). Torque setting for pin (1): 70 Nm (7 kgm) [5.2 Ft-lb]. NOTE From this point, proceed with the refitting of the swing arm by going through the removal procedu- re in reverse order, starting from REMOVING THE SWING ARM.
  • Page 199 Body work RS 50 NOTES 7-74 ch. 7 Release 00 2001-03...
  • Page 200 Via G. Galilei, 1 30033 Noale (VE) Tel. +39 (0) 41 - 5829111 Fax +39 (0) 41 - 441054 www.aprilia.com www.serviceaprilia.com Italy 8140250...

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