APRILIA RS 50 Instruction manual

Workshop manual
RS 50
aprilia s.p.a.
Via G. Galilei, 1
30033 Noale (VE)
Tel. +39 (0) 41 - 5829111
Fax +39 (0) 41 - 441054
www.aprilia.com
www.serviceaprilia.com
Italy
8140473
1024 Y
Produced by Fornacette (PI) - ITALY

Introduction
This manual provides basic information about ordinary
vehicle servicing procedures.
The data and illustrations that make up the manual
were up to date at the time of publication.
The manual is intended for aprilia dealers and their
qualified mechanics. Many concepts have been inten-
tionally omitted as they were considered superfluous.
Since this publication cannot provide exhaustive
mechanical knowledge, it is assumed that people who
make use of this manual have received a basic training
in mechanics and possess a working knowledge of
vehicle repairing techniques.
Repairing or checking the vehicle without such knowl-
edge would be ineffective and even dangerous.
As the repairing and checking procedures are not
described in full detail, special care should be taken to
avoid damage to property and personal injury.
With a view to providing its customers with the best
possible riding experience, aprilia is committed to
continually improving its products and the accompany-
ing documentation.
aprilia dealers and world branches are informed about
all major technical modifications and changes in
repairing procedures. Such modifications will be
covered in later editions of this manual.
Should any need or doubt arise about repairing and
checking procedures, do not hesitate to contact
aprilia’s Consumer Service (A.C.S.): they will be
pleased to provide any information you may require
and let you know of any technical modifications and
updates.
For further information, please refer to:
SPARE PARTS CATALOGUE # 323 X
Engine Workshop Manual # 966 X
Special Tooling Manual
The main features described herein remaining un-
changed, aprilia reserves the right to change its
models at any time.
The right to store this document in electronic form and
to adapt or reproduce it in whole or in part is reserved
worldwide.
The mention of third parties’ products and services is
made for the sole purpose of information and consti-
tutes no engagement.
aprilia assumes no responsibility about the perform-
ance and use of such products or services.
First edition: november 2000
Produced and printed by:
CLD s.r.l. editing division
Via D.Alighieri, 37/A - 56012 Fornacette (PI)
Tel. +39 (0)587 - 42 28 00
Fax +39 (0)587 - 42 28 01
www.cld.it
E-mail: [email protected]
On behalf of:
aprilia S.p.A.
Via G. Galilei, 1 - 30033 Noale (VE) - Italia
Tel. +39 (0)41 - 58 29 111
Fax +39 (0)41 - 44 10 54
www.aprilia.com
www.serviceaprilia.com
LIST OF SECTIONS
5
Cooling System
3
Engine
2
Periodic Maintenance
Operations
1
General Information
6
Electrical Equipment
7
Cycle Parts
4
Fuel System

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TABLE OF CONTENTS
Chapter 1
LOCATION OF SERIAL NUMBERS ...................................................................................................... 1-2
NOTES ON FUEL, LUBRICANTS, COOLANTAND OTHER ITEMS .................................................... 1-2
RUNNING-IN RULES.............................................................................................................................1-6
SPARE PARTS.......................................................................................................................................1-7
TECHNICAL DATA.................................................................................................................................1-7
LUBRICANT CHART..............................................................................................................................1-9
SPECIAL TOOLS OPT ...................................................................................................................1-10
GENERAL SPECIFICATIONS FOR TIGHTENING TORQUES ........................................................... 1-12
ABBREVIATIONS, SYMBOLS, ACRONYMS ...................................................................................... 1-13
Chapter 2
LUBRICATING POINTS.........................................................................................................................2-4
ARRANGEMENT OF INSTRUMENTS/CONTROLS ............................................................................. 2-5
INSTRUMENTS AND INDICATORS ......................................................................................................2-5
BATTERY ............................................................................................................................................... 2-6
LONG BATTERY INACTIVITY ...............................................................................................................2-9
SPARK PLUG ........................................................................................................................................2-9
AIR CLEANER ..................................................................................................................................... 2-11
ADJUSTING THE THROTTLE CONTROL .......................................................................................... 2-12
IDLINGADJUSTMENT ........................................................................................................................ 2-12
CONTROLS ON THE CARBURETTOR .............................................................................................. 2-13
CHECKING THE TRANSMISSION OIL LEVEL................................................................................... 2-13
CHANGING THE TRANSMISSION OIL............................................................................................... 2-15
MIXER OIL RESERVOIR .....................................................................................................................2-17
COOLANT............................................................................................................................................ 2-18
CHECKING AND RESTORING THE BRAKE FLUID LEVEL .............................................................. 2-22
FRONT BRAKE.................................................................................................................................... 2-23
REAR BRAKE ...................................................................................................................................... 2-25
RENEWING THE FRONT BRAKE FLUID ........................................................................................... 2-26
RENEWING THE REAR BRAKE FLUID.............................................................................................. 2-27
AIR-BLEEDING THE BRAKING SYSTEMS ........................................................................................2-28
ADJUSTING THE REAR BRAKE ........................................................................................................2-30
ADJUSTING THE CLUTCH .................................................................................................................2-31
ADJUSTING THE GEAR LEVER......................................................................................................... 2-31
STEERING...........................................................................................................................................2-32
DRIVE CHAIN ...................................................................................................................................... 2-33
PERIODIC MAINTENANCE AND ADJUSTMENTS............................................................................. 2-36
FUEL LINES.........................................................................................................................................2-38
BRAKE LINES......................................................................................................................................2-38
COOLANT LINES ............................................................................................................................... 2-38
MIXER OIL LINES............................................................................................................................... 2-39
REPLACING THE HEADLIGHT BULBS ............................................................................................. 2-39
REPLACING THE PARKING LIGHT BULB ........................................................................................ 2-40
REPLACING THE HIGH BEAM BULB................................................................................................ 2-40
REPLACING THE LOW BEAM BULB ................................................................................................ 2-41
REPLACING THE FRONTAND REAR TURN INDICATOR BULBS .................................................. 2-41
REPLACING THE REAR LIGHT BULB .............................................................................................. 2-42
TIGHTENING OF BOLTS AND NUTS ................................................................................................ 2-43
FASTENINGS ..................................................................................................................................... 2-44

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Chapter 3
ENGINE COMPONENTS THAT CAN BE REMOVED
WITHOUT REMOVING THE ENGINE FROM THE FRAME................................................................. 3-2
REMOVING THE ENGINEASSEMBLY FROM THE FRAME .............................................................. 3-3
Chapter 4
FUEL TANK........................................................................................................................................... 4-2
MAINTENANCE .................................................................................................................................... 4-3
CHECKING THE FUEL SUPPLY .......................................................................................................... 4-3
REMOVING THE FUEL COCK ............................................................................................................. 4-4
REMOVING THE CARBURETTOR ...................................................................................................... 4-4
REMOVING THE MIXER OIL RESERVOIR ......................................................................................... 4-6
Chapter 5
REMOVING THE RADIATOR ............................................................................................................... 5-2
REMOVING THE FILLER CAP............................................................................................................. 5-3
Chapter 6
INTRODUCTION................................................................................................................................... 6-2
RECOMMENDED EQUIPMENT........................................................................................................... 6-2
LOCATION OF COMPONENTS ........................................................................................................... 6-4
IGNITION CIRCUIT............................................................................................................................... 6-5
GENERAL FEEDING AND RECHARGE CIRCUIT............................................................................... 6-7
STARTING CIRCUIT............................................................................................................................. 6-9
SENSORS CIRCUIT ........................................................................................................................... 6-12
TURN INDICATORS CIRCUIT............................................................................................................ 6-13
HORN CIRCUIT .................................................................................................................................. 6-15
STOPLIGHTS CIRCUIT...................................................................................................................... 6-17
LIGHTING CIRCUIT............................................................................................................................ 6-19
LIGHTING CIRCUITASD ................................................................................................................... 6-20
BULBS ................................................................................................................................................ 6-24
CHANGING THE HEADLIGHT BULBS .............................................................................................. 6-24
CHANGING THE PARKING LIGHT BULB.......................................................................................... 6-24
CHANGING THE HIGH BEAM BULB ................................................................................................. 6-25
CHANGING THE LOW BEAM BULB.................................................................................................. 6-25
CHANGING THE FRONTAND REAR TURN INDICATOR BULBS.................................................... 6-26
CHANGING THE REAR LIGHT BULB................................................................................................ 6-26
ADJUSTING THE HEADLIGHT BEAM VERTICALLY ........................................................................ 6-27
CHANGING THE FUSE ...................................................................................................................... 6-27
CHECKING THE SWITCHES ............................................................................................................. 6-29
Chapter 7
HOW TO APPLY TRANSFERS............................................................................................................. 7-2
REMOVING THE RIDER SADDLE....................................................................................................... 7-4
REMOVING THE SADDLE LOCK ........................................................................................................ 7-4
REMOVING THE PASSENGER SADDLE............................................................................................ 7-4
REMOVING THE FAIRINGS................................................................................................................. 7-5
REMOVING THE FUEL TANK .............................................................................................................. 7-6
EMPTYING THE FUEL TANK ............................................................................................................... 7-7
REMOVING THEAIR FILTER BOX ...................................................................................................... 7-8
REMOVING THE HANDGRIP FROM THE LEFT HANDLEBAR .......................................................... 7-9
REMOVING THE ELECTRICAL CONTROLS FROM THE LEFT HANDLEBAR .................................. 7-9

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REMOVING THE CLUTCH LEVER .................................................................................................... 7-10
REMOVING THE THROTTLE CONTROL .......................................................................................... 7-11
REMOVING THE ELECTRICAL CONTROLS FROM THE RIGHT HANDLEBAR.............................. 7-12
REMOVING THE STOPLIGHT SWITCH ............................................................................................ 7-12
REMOVING THE FRONT BRAKE CONTROL ................................................................................... 7-13
REMOVING THE RIGHT HANDLEBAR ............................................................................................. 7-14
REMOVING THE LEFT HANDLEBAR................................................................................................ 7-14
REMOVING THE IGNITION SWITCH/STEERING LOCK .................................................................. 7-15
REMOVING THE REARVIEW MIRRORS .......................................................................................... 7-15
REMOVING THE FRONT FAIRING GLASS....................................................................................... 7-16
REMOVING THE FRONT FAIRING.................................................................................................... 7-16
REMOVING THE HEADLIGHT ........................................................................................................... 7-17
REMOVING THE DASHBOARD......................................................................................................... 7-17
REMOVING THE INSTRUMENT PANEL FRAME.............................................................................. 7-18
REMOVING THE FRONT MUDGUARD ............................................................................................. 7-19
REMOVING THE FRONT TURN INDICATORS ................................................................................. 7-19
REMOVING THE LOWER FAIRING................................................................................................... 7-20
REMOVING THE REAR FAIRING ...................................................................................................... 7-21
REMOVING THE REAR LIGHT.......................................................................................................... 7-22
REMOVING THE NUMBER-PLATE HOLDER.................................................................................... 7-22
REMOVING THE SADDLE SUPPORT COVER ................................................................................. 7-23
REMOVING THE REAR TURN INDICATORS.................................................................................... 7-23
REMOVING THE REAR MUDGUARD ............................................................................................... 7-24
REMOVING THE PASSENGER FOOTREST SUPPORT................................................................... 7-24
REMOVING THE PASSENGER FOOTREST..................................................................................... 7-25
REMOVING THE RIDER FOOTREST SUPPORT (LEFT SIDE)........................................................ 7-25
REMOVING THE RIDER FOOTREST SUPPORT (RIGHT SIDE)...................................................... 7-26
REMOVING THE RIDER FOOTREST................................................................................................ 7-27
REMOVING THE GEAR LEVER ........................................................................................................ 7-27
REMOVING THE REAR BRAKE LEVER ........................................................................................... 7-28
REMOVING THE EXHAUST SILENCER ........................................................................................... 7-28
REMOVING THE EXHAUST TERMINAL ........................................................................................... 7-30
CLEANING THE EXHAUST SILENCER AND THE EXHAUST TERMINAL ....................................... 7-31
REMOVING THE SIDE STAND .......................................................................................................... 7-32
REMOVING THE CHAIN GUIDE SHOE............................................................................................. 7-33
REMOVING THE SADDLE SUPPORT............................................................................................... 7-33
FRONT WHEEL .................................................................................................................................. 7-36
REMOVING THE FRONT WHEELASSEMBLY.................................................................................. 7-37
DISASSEMBLING THE FRONT WHEEL............................................................................................ 7-38
REINSTALLING THE FRONT WHEEL ............................................................................................... 7-40
FRONT BRAKE................................................................................................................................... 7-42
REPLACING THE FRONT BRAKE PADS .......................................................................................... 7-43
REMOVING THE FRONT BRAKE PUMP........................................................................................... 7-44
REMOVING THE BRAKE DISC.......................................................................................................... 7-44
FRONT FORK..................................................................................................................................... 7-45
REMOVING THE FRONT FORK ........................................................................................................ 7-46
DISASSEMBLING THE FORK............................................................................................................ 7-47
CHECKING COMPONENTS .............................................................................................................. 7-50
REASSEMBLING THE FORK............................................................................................................. 7-51
STEERING.......................................................................................................................................... 7-54
REMOVING THE STEERING ............................................................................................................. 7-55
CHECKING COMPONENTS .............................................................................................................. 7-56
REFITTING THE STEERING.............................................................................................................. 7-57

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REAR WHEEL .................................................................................................................................... 7-58
REMOVING THE REAR WHEELASSEMBLY .................................................................................... 7-59
REINSTALLING THE REAR WHEEL.................................................................................................. 7-61
REAR BRAKE ..................................................................................................................................... 7-63
REPLACING THE REAR BRAKE PADS ............................................................................................ 7-64
REMOVING THE REAR BRAKE DISC............................................................................................... 7-65
REMOVING THE REAR BRAKE PUMP............................................................................................. 7-65
REMOVING THE REAR SUSPENSION............................................................................................. 7-66
CHECKING THE SUSPENSION COMPONENTS.............................................................................. 7-67
REMOVING THE DRIVE CHAIN ........................................................................................................ 7-68
REMOVING THE SWING ARM .......................................................................................................... 7-69
DISASSEMBLING THE SWING ARM................................................................................................. 7-71
CHECKING COMPONENTS .............................................................................................................. 7-71
REASSEMBLING THE SWING ARM.................................................................................................. 7-72

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SAFETY WARNINGS
The following precautionary warnings are used throughout this manual in order to convey the following messages:
Safety warning. When you find this symbol on the vehicle or in the manual, be careful to the potential
risk of personal injury. Non-compliance with the indications given in the messages preceded by this
symbol may result in grave risks for your and other people’s safety and for the vehicle!
Indicates a potential hazard which may result in serious injury or even death.
Indicates a potential hazard which may result in minor personal injury or damage to the vehicle.
NOTE The word “NOTE” in this manual precedes important information or instructions.
PRECAUTIONS AND GENERAL INFORMATION
When repairing, disassembling and reassembling the vehicle, scrupulously observe the following recommenda-
tions.
The use of open flames is forbidden under all circumstances.
Before performing any servicing or checks, switch off the engine, remove the ignition key, allow the engine
and the exhaust system to cool down, and if possible lift the vehicle on solid level flooring using specific
equipment.
To avoid burns, pay special attention to hot engine and exhaust parts.
The vehicle is made up of inedible parts. On no account must any parts be bitten, sucked, chewed or
swallowed.
Unless otherwise specified, the reassembly of parts is carried out by following the disassembling proce-
dures in reverse order.
Any overlapping operations in cross-references to other chapters should be interpreted logically so as to
avoid unnecessary removal of components.
Never use fuel as a solvent to clean the vehicle.
Disconnect the battery negative (-) cable before performing any electric welding.
When two or more people are working at the same time, pay attention to the safety of each of them.
BEFORE REMOVING COMPONENTS
Remove any dirt, mud, dust and foreign bodies from the vehicle before removing any components.
Use the tools specially designed for this vehicle whenever necessary.
REMOVING COMPONENTS
Never loosen screws and nuts using tools other than the specific spanners.
Mark the positions on all connecting joints (pipes, cables, etc.) before separating them, and identify them with
different marks.
Clearly mark each part so it can be easily identified during reinstallation.
Clean and wash the removed components with a low-flash detergent.
Keep mating parts together, as they have adapted to one another through wear and tear. Some components must
be used in combination or replaced as a set.
Keep away from heat sources.
WARNING
WARNING
CAUTION

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REPLACING COMPONENTS
Never reuse circlips. Always replace removed circlips with new ones.
When fitting a new circlip, take care not to part its ends more than is required to fit it on the shaft.
After fitting a circlip, ensure that it is fully and firmly inserted in its seat.
Never use compressed air to clean the bearings.
IMPORTANT Bearings should always rotate freely, smoothly and silently, otherwise they must be replaced.
Only use GENUINE aprilia spares.
Always use the recommended lubricants and consumables.
If possible, lubricate parts before refitting them.
When tightening screws and nuts, start with the larger or the inner ones, and then proceed diagonally.
Carry out the tightening in successive steps before applying the full tightening torque.
Always replace self-locking nuts, seal rings, circlips, O-rings, cotter pins and screws (if the threads are damaged)
with new ones.
Clean all mating surfaces, oil seal rims and gaskets before refitting.
Apply a film of lithium grease to the oil seal rims.
Replace the oil seals and the bearings so that the marks or serial numbers face outwards (side in view).
Generously lubricate the bearings before fitting them.
Check that every component has been fitted properly.
After repairing or servicing any parts, carry out preliminary checks and test the vehicle on private ground or in a
low-traffic area.
USING THE MANUAL
HOW TO CONSULT THE MANUAL
The manual is divided into chapters, each corresponding to a major type of components.
For easy reference, refer to the TABLE OF CONTENTS.
Unless otherwise specified, parts are reassembled by following the disassembling procedures in reverse order.
The terms “left” and “right” refer to the rider sitting on the vehicle in a normal riding position.
Refer to the Operation and Maintenance Manual for information on how to operate and maintain the vehicle.
In this manual the various versions are indicated by the following symbols:
automatic light switching version (Automatic Switch-on Device)
optional
CAUTION

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NOTES

General Information
General Information RS 50
chap. 1
Release 00 2001-1 1-1
1

General Information RS 50
Release 00 2001-1
chap. 1
1-2
LOCATION OF SERIAL NUMBERS
These numbers are needed for registration purposes.
IMPORTANT Tampering with serial numbers is
subject to severe penalties. In particular, tampering
with the frame number immediately voids the war-
ranty.
FRAME NUMBER
The frame number is stamped on the right side of the
steering head tube.
ENGINE NUMBER
The engine number is stamped on the rear side, near
the pinion.
NOTES ON FUEL, LUBRICANTS, COOLANT AND OTHER ITEMS
FUEL
The fuel used in internal combustion engines is highly flammable and can be explosive under certain
conditions.
Refuelling and servicing should be carried out in a well ventilated place after switching off the engine.
Do not smoke while refuelling or in the presence of fuel fumes. Avoid contact with open flames, sparks and
any other potential source of ignition or explosion.
Avoid spilling fuel from the tank filler as it may catch fire on contact with the hot engine surfaces.
Should any fuel be inadvertently spilled, be sure to dry up the area before starting the engine.
Since fuel dilates when exposed to heat and direct sunlight, avoid filling the tank to the brim.
Carefully close the tank cap after refuelling.
Do not allow fuel to come into contact with the skin and avoid ingesting it or inhaling its fumes. Do not
transfer fuel from one vessel into another using a length of tube.
DO NOT DISPOSE OF FUEL IN THE ENVIRONMENT.
KEEP OUT OF REACH OF CHILDREN.
Only use unleaded premium petrol with a minimum octane number of 95 (RON) or 85 (MON).
CAUTION

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TRANSMISSION OIL
Transmission oil can cause serious damage to the skin if handled every day and for long periods.
Wash your hands carefully after using the oil.
Do not dispose of the oil in the environment.
Put it in a sealed container and take it to the filling station where you usually buy it or to an oil salvage
center.
In case any maintenance operation has to be carried out, it is advisable to use latex gloves.
Renew the transmission oil after the first 500 km (300 mi) and then every 8,000 km (5,000 mi) (*). See CHANGING
THE TRANSMISSION OILAND THE ENGINE OIL FILTER.
Transmission oil (recommended):
F.C., SAE 75W-90 or
GEAR SYNTH
Alternatively, use brand-name oils with performance complying with or exceeding the A.P.I. GL-4 specifications.
FORK OIL
Fork oil can cause serious damage to the skin if handled every day and for long periods.
Wash your hands carefully after using the oil.
Do not dispose of the oil in the environment.
Put it in a sealed container and take it to the filling station where you usually buy it or to an oil salvage
center.
In case any maintenance operation has to be carried out, it is advisable to use latex gloves.
The response of the suspension can be partly altered by changing the adjustment of the shock absorbers
and/or the viscosity of the oil they contain.
Standard oil viscosity: SAE 20W.
Viscosity grades can be chosen according to the desired vehicle geometry (SAE 5W soft, SAE 20W stiff).
The two products can be used in different percentages until the desired response is obtained. The viscos-
ity of F.A. and FORK does not change much with temperature. As a result, the dampening
response remains constant.
Fork oil (recommended):
F.A. 5W fork oil or F.A. 20W fork oil;
Alternatively, FORK 5W or FORK 20W.
If an intermediate action between those offered by F.A. 5W end F.A. 20W or by FORK 5W end
FORK 20W, is desired, the products can be mixed as follows:
SAE 10W = F.A. 5W 67% by volume + F.A. 20W 33% by volume, or FORK 5W 67% by volume +
FORK 20W 33% by volume.
SAE 15W = F.A. 5W 33% by volume + F.A. 20W 67% by volume, or FORK 5W 33% by volume +
FORK 20W 67% by volume.
WARNING
WARNING

General Information RS 50
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1-4
MIXER OIL
Mixer oil can cause serious damage to the skin if handled every day and for long periods.
Wash your hands carefully after using the oil.
Do not dispose of the oil in the environment.
Put it in a sealed container and take it to the filling station where you usually buy it or to an oil salvage
center.
In case any maintenance operation has to be carried out, it is advisable to use latex gloves.
Mixer oil (recommended):
PRO GPX 2 or
2T FORMULA RACING
Alternatively, use brand-name oils with performance complying with or exceeding the ISO-L-ETC ++, A.P.I. TC ++
specifications.
BRAKE FLUID
IMPORTANT The vehicle is equipped with front and rear disc brakes with separate hydraulic circuits.
The following information refers to a single hydraulic circuit but applies to both.
Brake fluid can cause irritation if it comes into contact with the skin or the eyes.
Carefully wash any parts of the body that should happen to come into contact with the fluid. Contact an
ophthalmologist or a physician if the fluid comes into contact with the eyes.
DO NOT DISPOSE OF THE FLUID IN THE ENVIRONMENT.
KEEP OUT OF REACH OF CHILDREN.
When handling brake fluid, take care not to spill it on plastic and painted parts as they would be damaged.
Check the brake fluid level every 4,000 km (2,500 mi) (CHECKING AND RESTORING THE FRONT BRAKE
FLUID LEVEL and CHECKING AND RESTORING THE REAR BRAKE FLUID LEVEL). Renew the fluid every
year (RENEWING THE FRONT BRAKE FLUID and RENEWING THE REAR BRAKE FLUID).
Brake fluid (recommended):
F.F., DOT 5 (DOT 4 compatible) or
BRAKE 5.1, DOT 5 (DOT 4 compatible).
Do not use brake fluids other than those prescribed. To avoid damaging the braking system, never mix
different types of fluids when topping up.
Never use brake fluid taken from an old container, or from a container that has been open for a long time.
Sudden changes in brake play or a spongy feel of the brake levers are due to problems in the hydraulic
circuits.
Take special care in ensuring that the brake discs and the brake linings are not oily or greasy, especially
after checking or servicing the brakes.
Ensure that the brake lines are not twisted or worn.
Take care not to let any water or dust into the brake circuit.
Latex gloves are recommended for all maintenance operations involving the hydraulic circuit.
WARNING
WARNING
CAUTION

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COOLANT
The coolant is harmful if ingested. Contact with the skin or the eyes may cause irritation. Should the liquid
come into contact with the skin or the eyes, generously rinse with water and seek medical attention.
If the fluid is ingested, cause vomiting, generously rinse the mouth and throat with water and immediately
seek medical attention.
DO NOT DISPOSE OF THE COOLANT IN THE ENVIRONMENT.
KEEP OUT OF REACH OF CHILDREN.
Take care not to spill any coolant on hot engine parts as it may catch fire and produce invisible flames.
Latex gloves are recommended for all maintenance operations.
Do not use the vehicle if the coolant level is below the minimum.
Check the coolant level before starting off and every 2,000 km (1,250 mi) (CHECKINGAND RESTORING THE
COOLANT LEVEL). Renew the coolant every two years (RENEWING THE COOLANT).
The cooling solution is composed of 50 per cent water and 50 per cent antifreeze. This mixture is ideal for most
operating temperatures and ensures sufficient protection against corrosion.
It is advisable to use the same mixture during the hot season as this reduces evaporation and the need for frequent
replenishing.
This also reduces evaporation and the formation of mineral salts deposits in the radiator and maintains the cooling
system in perfect working order.
If the outside temperature is below 0°C, frequently check the cooling circuit and if necessary increase the
antifreeze concentration (up to 60 per cent).
To avoid damaging the engine, always use distilled water in the cooling solution.
Engine coolant (recommended):
ECOBLU -40°C (-104°F) or
COOL
Depending on the freezing temperature of the cooling mixture to be obtained, add the following coolant percent-
ages to the water:
IMPORTANT Different antifreezes have different characteristics. The degree of protection provided by each
product is specified on its label.
Only use nitrite-free antifreeze and anticorrosive providing protection to temperatures of at least -35°C (-
95°F).
Freezing point
°C (°F) Coolant percentage by volume
-20°(-68°)
-30°(-86°)
-40°(-104°)
35
45
55
WARNING
WARNING
CAUTION

General Information RS 50
Release 00 2001-1
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1-6
CARBON MONOXIDE
Whenever the engine needs to be run in order to carry out some operation, ensure that this is done in the open air
or in a well-ventilated room.
Never run the engine in a closed environment unless the place is equipped with an exhaust system.
Exhaust gases contain carbon monoxide, a poisonous gas that may cause fainting or even death.
Run the engine in an open space or in a closed space equipped with an exhaust system.
HIGH TEMPERATURE COMPONENTS
The engine and the exhaust components reach high temperatures during use and remain hot for some time
even after the engine has been switched off.
Before handling these components, put on insulating gloves or wait for the engine and the exhaust system
to cool down.
RUNNING-IN RULES
After the first 500 km (312 mi), carry out the checking operations indicated in the column “After running-in”
of the REGULAR SERVICE INTERVALS CHART, in order to avoid hurting yourself or other people and/or
damaging the vehicle.
The running-in of the engine is primary to ensure its correct functioning and its correct functioning. If possible, drive
on hilly roads and/or roads with many bends, so that the engine, the suspensions and the brakes undergo a more
effective running-in.
For the first 500 km (312 mi), keep to the following indications:
0-100 km (0-62 mi)
During the first 100 km (62 mi) put on the brakes with caution, avoiding sharp and prolonged brakings.
This ensures a correct bedding-in of the pads on the brake disc.
0-300 km (0-187 mi)
Do not keep the throttle grip open more than one half for long stretches.
300-500 km (187-312 mi)
Do not keep the throttle grip open more than three-fourths for long stretches.
WARNING
WARNING
WARNING

General Information RS 50
chap. 1
Release 00 2001-1 1-7
1
SPARE PARTS
Only use Genuine aprilia Spares.
All Genuine aprilia Spares are high-quality parts specially designed and manufactured for aprilia vehicles.
Using NON-genuine aprilia spares may result in damage and poor performance.
TECHNICAL DATA
CONTINUED 
DIMENSIONS
Max. length
Max. length (rear mudguard extension included )
Max. height (front part of the fairing included)
Seat height
Distance between centres
Min. ground clearance
Weight ready for starting
1920 mm (75.6 in)
1985 mm (78.1 in)
1155 mm (45.5 in)
810 mm (31.9 in)
1280 mm (50.4 in)
170 mm (6.7 in)
115 Kg (253.5 lbs)
Max. width 675 mm (26.6 in)
ENGINE
Type
Number of cylinders
Total displacement
Bore / stroke
Compression ratio
Starting
Engine idling
rpm
Clutch
Cooling
one-cylinder, 2-stroke with laminar suction.
Separate lubrication with variable strength automatic mixer
(1.0 - 3.0 %). 1
49,75 cm3(3 cu.in3)
40,3 mm / 39,0 mm (1.6 in / 1.5 in)
12 ±0,5 : 1
electric
1100 ±100 rpm
multidisc in oil bath, with manual control on the left side of
the handlebar. liquid-cooled
CAPACITY
Fuel (reserve included)
Coolant
Seats
Vehicle max. load (driver + luggage)
Vehicle max. load (driver+passenger+luggage)
2,6l / 5.5 gals (mechanical reserve)
0,9l / 1.9 gals(50% water + 50% antifreeze with ethylene glycol)
n°1 (2 in the countries where this is allowed)
105 Kg (231.5 lbs)
396,8 lbs / 180 Kg ( in the countries where this is allowed )
Fuel reserve
Transmission oil 820 cm3(50 cu.in3)
13l (27.4 gals)
2 stroke oil (reserve included) 1,6l (3.4 gals)
2 stroke oil reserve 0,35l (0.7 gals)
Front fork oil 285 cm3/ 17.4 cu.in3(for each rod)
Type mechanical, 6 gears with foot control on the left side of the
engine
TRANSMISSION
Ratio 1st
Primary
Secondary
Final ratio
Total ratio
20/71 = 1:3.550
12/36 = 1:3.000
12/47 = 1:3.916
1:41.712
GEAR RATIOS
CAUTION

General Information RS 50
Release 00 2001-1
chap. 1
1-8
CONTINUED 
Number
Model DELLORTO SHA 14/12M
CARBURETTOR 1
Fuel
Leaded or unleaded premium grade petrol (4 Stars ) according to
the DIN 51600 standard, min. O.N. 95 (N.O.R.M.) and 85 (N.O.M.M.)
FUEL SUPPLY
Fuel
unleaded petrol according to the DIN 51607 standard, min.
O.N. 95 (N.O.R.M.) and 85 (N.O.M.M.)
Type in aluminium
FRAME
Steering inclination angle 24°(- 75°F)
Fore stroke 102 mm (4 in)
TYRES
Front 90/80 17”46S; 90/80 17”46P
Rear 110/80 17”57S; 110/80 17”57P
INFLATION PRESSURE FOR SOLO RIDER
Front 170 kPa (24.6 Psi / 1.7 bar)
Rear 190 kPa (27.5 Psi / 1.9 bar)
INFLATION PRESSURE FOR RIDER AND PASSENGER (in the countries where this is allowed)
Front 180±10 kPa (1.8±0.1 bar / 26±1.45 Psi )
Rear 210±10 kPa (2.1±0.1 bar / 30.4±1.45 Psi)
Type C.D.I.
IGNITION
Spark advance 20°±1°(68°F ±34°F) before T.D.C.
Front hydraulically operated telescopic fork
SUSPENSIONS
Wheel stroke 110 mm (4.3 in)
Rear hydraulic adjustable mono-shock absorber
Wheel stroke 120 mm (4.7 in)
Front disc brake - Ø280 mm (11 in) - with hydraulic transmission
BRAKES
Rear disc brake - Ø220 mm (8.6 in) - with hydraulic transmission
Type light alloy
WHEEL RIMS
Front 2,50 x 17”
Rear 3,00 x 17”
Ratio 2nd
Secondary
Total ratio 16/33 = 1:2.062
1:28.677
GEAR RATIOS
Ratio 3rd
Secondary
Total ratio 19/29 = 1:1.526
1:21.222
Ratio 4th
Secondary
Total ratio 22/27 = 1:1.227
1:17.064
Ratio 5th
Secondary
Total ratio 24/25 = 1:1.042
1:14.483
Ratio 6th
Secondary
Total ratio 25/24 = 1:0.960
1:13.348

General Information RS 50
chap. 1
Release 00 2001-1 1-9
1
LUBRICANT CHART
Gearbox oil (recommended): F. C., SAE 75W - 90 or GEAR SYNTH, SAE 75W - 90.
As an alternative to the recommended oil, it is possible to use high-quality oils with characteristics in compliance
with or superior to the A.P.I. GL-4 specifications.
2 stroke oil (recommended): PRO GPX 2 or 2T FORMULA RACING.
As an alternative to the recommended oil, use high-quality oils with characteristics in compliance with or superior to
the ISO-L-ETC++, A.P.I. TC++ specifications.
Fork oil (recommended): F. A. 5W or F. A. 20W fork oil;
As an alternative FORK 5W or FORK 20W.
If you need an oil with intermediate characteristics in comparison with the two recommended products, these can
be mixed as indicated below:
SAE 10W = F. A. 5W 67% of the volume + F. A. 20W 33% of the volume, or
FORK 5W 67% of the volume + FORK 20W 33% of the volume;
SAE 15W = F. A. 5W 33% of the volume + F. A. 20W 67% of the volume, or
FORK 5W 33% of the volume + FORK 20W 67% of the volume.
Bearings and other lubrication points (recommended): AUTOGREASE MP or GREASE 30.
As an alternative to the recommended product, use high-quality grease for rolling bearings, working temperature
range -30°C.... +140°C (86°F…+ 284°F), dripping point 150°C... 230°C (302°F…446°F), high protection against
corrosion, good resistance to water and oxidation.
Protection of the battery poles: neutral grease or vaseline.
Spray grease for chains (recommended): CHAIN SPRAY or CHAIN LUBE.
Use new brake fluid only.
Brake fluid (recommended): F. F., DOT 5 (Compatible DOT4) or BRAKE 5.1, DOT 5 (Compatible DOT4).
Use only antifreeze and anticorrosive without nitrite, ensuring protection at -35°C (-95°F) at least.
Engine coolant (recommended): ECOBLU - 40°C (- 104°F) or COOL.
Standard NGK R BR9ES
SPARK PLUG
Alternative CHAMPION RN1C
NGK R BR8ES
Spark plug gap 0.6 - 0.7 mm (0.02 - 0.03 in)
Battery
Fuse
Generator 7.5 A
12 V - 105 W
ELECTRIC 12 V - 4 Ah
Low beam
High beam
Parking light 12 V - 35 W
12 V - 5 W
BULBS 12 V - 35 W
Direction indicators
Rear parking light/ number plate light/stoplight 12 V - 5 / 21 W
12 V - 10 W
Revolution counter 12 V - 5 W
Speedometer 12 V - 3.4 W
Coolant temperature indicator 12 V - 1.2 W
Neutral
Right direction indicators
High beam 12 V - 1.7 W
12 V - 1.7 W
WARNING LIGHTS 12 V - 1.7 W
2 stroke oil reserve
Left direction indicators 12 V - 1.7 W
12 V - 1.7 W
Low beam 12 V - 1.7 W
WARNING
WARNING

General Information RS 50
Release 00 2001-1
chap. 1
1-10
SPECIAL TOOLS
Proper removal and refitting of parts, as well as
correct adjustment of components, can only be
obtained with suitable tools.
Special tools prevent possible damage due to the use
of unsuitable equipment and/or improper techniques.
The following is a list of the tools specially designed
for this vehicle.
Should any generic special tools be needed, refer to
the Special Tooling Manual.
Before using a special tool, consult any accompa-
nying documentation.
WARNING
Pos. Tool name
and function
1
2
3
Stand support peg
Rear stand
Swing arm pivot adjusting bush spanner
2
1
3
Code
8140204
8705021
8101945

General Information RS 50
chap. 1
1-11
1
Release 00 2000-11
PLACING THE VEHICLE ON THE REAR STAND
Loosen knob (1).
Remove fork-shaped support (2) and pull it out of the
stand seat.
Insert support peg (3).
Repeat the above operations on the opposite side of
the stand.
Lift the vehicle by acting only on the two swing
arm bars.
Rear stand support peg: 8140204
CAUTION
Insert the stand from the back of the vehicle and
position it so that the two support pegs (3) are in-
serted as follows:
- The right-hand peg between the brake caliper and
the brake line connection on the swing arm (Pos. A).
- The left-hand peg between the rear sprocket and the
chain (Pos. B).
Remove support pegs (3) and bring them into contact
with the swing arm.
Tighten the two knobs (1).
IMPORTANT A second operator is needed to help
to keep the vehicle in a vertical position with both
wheels resting on the ground.
Rest one foot on the rear part of stand (4).
Push stand (4) downwards to travel end (see figure).
Rear stand: 8705021
3
1
2
A
B
4