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
8140250
979 X
Produced by Fornacette (PI) - ITALY

Introduction
This manual contains information on how to perform
the usual vehicle service procedures. 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
and their trained, experienced mechanics.
The descriptions of many service and repair opera-
tions have been intentionally omitted, as it is assumed
that the users of this manual have basic mechanical
training and basic knowledge of the procedures used
for motor vehicle repair, as well as safety rules neces-
sary to ensure their safety and that of the public while
repairing motor vehicles. Therefore, it is imperative
that you do not attempt to perform any maintenance
or repair procedure with which you are not thoroughly
familiar, and fully qualified to perform. Such an at-
tempt can result in defective repairs, which can be
dangerous both to you, to the owner or user of the
vehicle, and to the public in general.
The information and illustrations in this manual are
current as of the manual’s date of issue.
Since aprilia s.p.a. continually improves its products,
there may be some differences between the vehicle
you are servicing and the illustrations and instructions
given in this manual. If you have any questions
regarding the applicability of any service procedure
given in this manual, contact aprilia consumer ser-
vices (A.C.S.). A.C.S. Technical Counselors will be
able to assist you with any problems you might face
as well as providing you with information on any
updates and technical changes to the vehicle you are
servicing.
Any change made to technical specifications and
vehicle servicing procedures will be documented and
distributed to aprilia dealers all over the world.
These changes will be incorporated in later editions of
this manual.
For further information refer to:
SPARE PARTS CATALOGUE # 323 X;
engine workshop manual # 966 X;
service tools manual.
aprilia s.p.a. reserves the right to modify specifica-
tions and characteristics of any of its models at any
time. aprilia makes no representation that this manual
covers any such changes.
This manual is protected by copyright in all countries.
Electronic storage and the total or partial reproduction
and adaptation by any means is prohibited.
The mention of products or services supplied by
entities other than aprilia is for information purposes
only and is not binding in any way.
aprilia s.p.a. is not responsible for the performance or
use of any of these products.
First edition: March 2001
Produced and printed by:
CLD s.r.l. Technical manuals 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
Routine maintenance
operations
1
General information
6
Electrical system
7
Body work
4
Fuel system

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CONTENTS
Chapter 1
POSITION OF SERIAL NUMBERS .......................................................................................................1-2
SAFETY WARNINGS FOR FUEL, LUBRICANTS COOLANTAND 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............................................................................................................................... 1-12
LUBRICANT CHART............................................................................................................................1-14
SPECIAL TOOLS ............................................................................................................................1-15
GENERAL SPECIFICATIONS FOR TORQUE WRENCH SETTINGS ................................................ 1-17
ABBREVIATIONS / SYMBOLS / INITIALS .......................................................................................... 1-18
Chapter 2
SERVICING SCHEDULE.......................................................................................................................2-3
LUBRICATION POINTS.........................................................................................................................2-4
ARRANGEMENT OF THE INSTRUMENTS / CONTROLS ...................................................................2-5
INSTRUMENTS AND INDICATORS ......................................................................................................2-5
BATTERY...............................................................................................................................................2-6
CHECKING AND CLEANING THE TERMINALS................................................................................... 2-7
REMOVING THE BATTERY ..................................................................................................................2-7
CHECKING THE ELECTROLYTE LEVEL ............................................................................................. 2-8
RECHARGING THE BATTERY .............................................................................................................2-8
INSTALLING THE BATTERY .................................................................................................................2-9
LONG PERIOD OF BATTERY NON-USE .............................................................................................2-9
SPARK PLUG ........................................................................................................................................2-9
AIR CLEANER ..................................................................................................................................... 2-11
ADJUSTING THE THROTTLE CONTROL .......................................................................................... 2-12
IDLING ADJUSTMENT ........................................................................................................................ 2-12
CARBURETOR CONTROLS ............................................................................................................... 2-13
COLD START LEVER .......................................................................................................................... 2-13
CHECKING THE GEARBOX OIL ........................................................................................................2-13
CHECKING TOPPING UP ................................................................................................................... 2-14
CHANGING THE GEARBOX OIL ........................................................................................................2-15
2 STROKE OIL TANK .......................................................................................................................... 2-17
COOLANT............................................................................................................................................2-18
CHECKING AND TOPPING UP THE BRAKE FLUID .......................................................................... 2-22
FRONT BRAKE.................................................................................................................................... 2-23
REAR BRAKE ......................................................................................................................................2-25
CHANGING THE FRONT BRAKE FLUID............................................................................................2-26
CHANGING THE REAR BRAKE FLUID ..............................................................................................2-27
BLEEDING THE BRAKE CIRCUITS.................................................................................................... 2-28
ADJUSTING THE REAR BRAKE ........................................................................................................2-30
ADJUSTING THE CLUTCH ................................................................................................................. 2-31
ADJUSTING THE SHIFT LEVER......................................................................................................... 2-31
STEERING...........................................................................................................................................2-32
DRIVE CHAIN ......................................................................................................................................2-33
ROUTINE MAINTENANCE AND SERVICING OPERATIONS ............................................................ 2-36
FUEL LINES.........................................................................................................................................2-38
BRAKE PIPES/HOSES........................................................................................................................2-38
COOLING.............................................................................................................................................2-38
SYSTEM HOSES.................................................................................................................................2-38
2 STROKE OIL PIPES/HOSES............................................................................................................ 2-39
TIGHTENING NUTS AND BOLTS .......................................................................................................2-39

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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 ............................................................................................................... 4-3
REMOVING THE FUEL VALVE ............................................................................................................. 4-4
REMOVING THE CARBURETOR ......................................................................................................... 4-4
REMOVING THE 2 STROKE OILTANK................................................................................................4-6
Chapter 5
REMOVING THE RADIATOR ................................................................................................................5-2
REMOVING THE FILLER CAP..............................................................................................................5-3
Chapter 6
INTRODUCTION....................................................................................................................................6-2
RECOMMENDED EQUIPMENT............................................................................................................ 6-2
MAIN WIRING DIAGRAM ......................................................................................................................6-3
LOCATION OF COMPONENTS ............................................................................................................6-4
IGNITION CIRCUIT................................................................................................................................6-5
RECHARGE AND GENERAL POWER SUPPLY CIRCUIT ................................................................... 6-7
STARTER CIRCUIT ............................................................................................................................... 6-9
SENSOR CIRCUIT ..............................................................................................................................6-12
DIRECTION INDICATORS CIRCUIT................................................................................................... 6-13
HORN CIRCUIT ...................................................................................................................................6-15
BRAKING LIGHTS CIRCUIT ...............................................................................................................6-17
LIGHT CIRCUIT ................................................................................................................................... 6-19
LIGHT CIRCUIT .............................................................................................................................. 6-20
ELECTRICAL CONNECTORS............................................................................................................. 6-23
BULBS .................................................................................................................................................6-24
CHANGING THE HEADLIGHT BULBS ...............................................................................................6-24
CHANGING PARKING LIGHT BULB...................................................................................................6-24
CHANGING HIGH BEAM BULB .......................................................................................................... 6-25
CHANGING LOW BEAM BULB ........................................................................................................... 6-25
CHANGING THE FRONTAND REAR TURN SIGNAL BULBS ...........................................................6-26
CHANGING THE REAR LIGHT BULB.................................................................................................6-26
ADJUSTING THE HEADLIGHT BEAM VERTICALLY ......................................................................... 6-27
ADJUSTING THE HEADLIGHT BEAM HORIZONTALLY.................................................................... 6-27
CHANGE FUSES.................................................................................................................................6-29
CHECKING THE SWITCHES .............................................................................................................. 6-31
Chapter 7
APPLYING THE TRANSFERS............................................................................................................... 7-2
REMOVING THE RIDER SADDLE........................................................................................................7-4
REMOVING THE SADDLE LOCK ......................................................................................................... 7-4
REMOVING THE PASSENGER SADDLE .............................................................................................7-4
REMOVING THE SIDE FAIRINGS ........................................................................................................7-5
REMOVING THE FUEL TANK ...............................................................................................................7-6
EMPTYING THE FUEL TANK ................................................................................................................7-7
REMOVING THE AIR BOX .................................................................................................................... 7-8

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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 .................................................................................... 7-13
REMOVING THE RIGHT HANDLEBAR ..............................................................................................7-14
REMOVING THE LEFT HANDLEBAR................................................................................................. 7-14
REMOVING THE IGNITION SWITCH/STEERING LOCK ................................................................... 7-15
REMOVING THE REAR VIEW MIRRORS .......................................................................................... 7-15
REMOVING THE FRONT FAIRING..................................................................................................... 7-16
REMOVING THE WINDSHIELD.......................................................................................................... 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 DIRECTION INDICATORS ........................................................................ 7-19
REMOVING THE LOWER FAIRING....................................................................................................7-20
REMOVING THE REAR FAIRING .......................................................................................................7-21
REMOVING THE REAR LIGHT........................................................................................................... 7-22
REMOVING THE LICENSE PLATE HOLDER..................................................................................... 7-22
REMOVING THE PILLAR COVER ...................................................................................................... 7-23
REMOVING THE REAR TURN SIGNALS........................................................................................... 7-23
REMOVING THE REAR MUDGUARD ................................................................................................ 7-24
REMOVING THE REAR FOOTREST SUPPORTS ............................................................................. 7-24
REMOVING THE REAR FOOTRESTS ............................................................................................... 7-25
REMOVING THE FRONT FOOTREST SUPPORT (LEFT SIDE)........................................................ 7-25
REMOVING THE FRONT FOOTREST SUPPORT (RIGHT SIDE) ..................................................... 7-26
REMOVING THE FRONT FOOTREST................................................................................................ 7-27
REMOVING THE SHIFT LEVER .........................................................................................................7-27
REMOVING THE BRAKE PEDAL ....................................................................................................... 7-28
REMOVING THE EXHAUST PIPE ...................................................................................................... 7-28
REMOVING THE MUFFLER ............................................................................................................... 7-30
CLEANING THE EXHAUST PIPE AND MUFFLER ............................................................................. 7-31
REMOVING THE SIDE STAND ...........................................................................................................7-32
REMOVING THE CHAIN GUIDE......................................................................................................... 7-33
REMOVING THE PILLAR .................................................................................................................... 7-33
FRONT WHEEL ................................................................................................................................... 7-36
REMOVING THE COMPLETE FRONT WHEEL.................................................................................. 7-37
DISASSEMBLING THE FRONT WHEEL............................................................................................. 7-38
REASSEMBLY FRONT WHEEL ..........................................................................................................7-40
FRONT BRAKE.................................................................................................................................... 7-42
CHANGING THE FRONT BRAKE PADS............................................................................................. 7-43
REMOVING THE FRONT BRAKE MASTER CYLINDER.................................................................... 7-44
REMOVING THE BRAKE DISC........................................................................................................... 7-44
FRONT FORK...................................................................................................................................... 7-45
REMOVING THE FRONT FORK .........................................................................................................7-46
DISASSEMBLING THE FORK............................................................................................................. 7-47
CHECKING THE COMPONENTS ....................................................................................................... 7-50
REFITTING THE FORK ....................................................................................................................... 7-51
STEERING...........................................................................................................................................7-54
REMOVING THE STEERING .............................................................................................................. 7-55
CHECKING THE COMPONENTS ....................................................................................................... 7-56
REFITTING THE STEERING............................................................................................................... 7-57

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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..............................................................................................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
REASSEMBLING THE SWING ARM................................................................................................... 7-72

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SAFETY WARNINGS
Throughout this manual, you will see the following symbols:
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.
It also indicates that serious and permanent damage to the vehicle is possible.
This statement indicates a potential hazard which may result in some personal injury, or damage to the
vehicle.
NOTE The word “NOTE” in this manual precedes important information or instructions to which special attention
must be given.
GENERAL SAFETY RULES
CARBON MONOXIDE
If it is necessary to run the engine in order to carry out maintenance operation, make sure that the area in wich you
are operating is properly ventilated.
Never run the engine in enclosed spaces.
If it is necessary to work indoors, use an exhaust evacuation system.
The exhaust fumes contain carbon monoxide, a poisonous gas that can cause loss of consciousness and
even death.
GASOLINE
Work in a well ventilated area. Keep cigarettes, flames or sparks away from the work area and from the place
where gasoline is stored.
Gasoline is extremely flammable and becomes explosive under certain conditions.
KEEP GASOLINE AWAY FROM CHILDREN.
HOT COMPONENTS
The engine and the components of the exhaust system become very hot and remain hot for some time
after the engine has been stopped.
Before handling these components, wear insulating gloves or walt until the engine and the exhaust system
have cooled down.
WARNING
CAUTION
WARNING
WARNING
WARNING

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USED ENGINE OIL AND FORK OIL
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.
KEEP OIL AWAY FROM CHILDREN.
BRAKE FLUID
The brake fluid can damage painted, plastic or rubber parts. When performing maintenance operations on
the braking system, place a clean shop towel on these parts.
Always wear goggles when servicing the brake system with brake fluid.
Brake fluid is extremely destructive to your eyes.
If you should accidentally get brake fluid in your eyes, flush immediately with a large quantity of cool clear
water and seek professional medical assistance immediately.
KEEP BRAKE FLUID AWAY FROM CHILDREN.
CLUTCH CONTROL FLUID
The clutch control fluid can damage painted, plastic or rubber parts.
When performing maintenance operations on the clutch control system, place a clean shop towel on these
parts.
Always wear goggles when servicing the clutch control system with clutch control fluid.
Clutch control fluid is extremely destructive to your eyes.
If you should accidentally get clutch control fluid in your eyes, flush immediately with a large quantity of
cool clear water and seek professional medical assistance immediately.
KEEP CLUTCH CONTROL FLUID AWAY FROM CHILDREN.
COOLANT
In certain conditions, the ethylene glycol contained in the engine coolant is flammable: its flame is invisible, but you
can be burned anyway.
Avoid spilling the engine coolant on the exhaust system or on the engine components.
They may be hot enough to cause the coolant to ignite and burn without a visible flame.
The coolant (ethylene glycol) can cause skin irritation and is poisonous if swallowed.
Engine coolant is sweet tasting, and therefore extremely attractive to pets and other animals, as well as
being extremely toxic.
Do not leave coolant in an open container where animals may be able to drink it.
KEEP COOLANT AWAY FROM CHILDREN.
Do not remove the radiator cap when the engine is hot. The coolant is under pressure and may cause
burns.
WARNING
CAUTION
CAUTION
WARNING

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BATTERY HYDROGEN GAS AND ELECTROLYTE
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.
Always wear tight fitting goggles and protective clothing when handling battery electrolyte.
It is particularly important for you to protect your eyes, since even a minuscule amount of battery acid can
destroy your vision.
Should you accidentally get even the smallest amount of battery acid on your skin or eyes, immediately
flush with large quantities of clear cool water and immediately seek professional medical attention.
The electrolyte is poisonous.
If the electrolyte is accidentally swallowed, drink large quantities of water or milk and then milk of magne-
sia or vegetable oil.
Seek professional medical attention immediately.
KEEP BATTERIES AND ELECTROLYTE AWAY FROM CHILDREN.
PRECAUTIONS AND GENERAL INFORMATION
Follow with care these recommendations when repairing, disassembling and reassembling the vehicle.
The use of open flames is forbidden for any type of operation.
Before commencing any service or inspection operation on the vehicle, switch off the engine and remove
the key, wait until the engine and the exhaust system have cooled down and, if possible, raise the vehicle
with the suitable equipment onto firm flat ground.
In order to avoid burns, be careful not to touch any parts of the engine or exhaust systems which have not
cooled down completely.
The brakes also get quite hot in operation.
Be sure that the brakes have cooled thoroughly before beginning any service operations.
Avoid the temptation to hold any hardware or other part of the vehicle in your mouth while working on the
vehicle.
No part of the motorscooter is edible and some of the coatings, plastics, and platings, etc. are noxious if
not outright toxic.
If not expressly described, the reassembly of the units is carried out by reversing the order of operations.
Handle fuel with the greatest caution.
See gasoline warning. Never use fuel as a solvent for cleaning the vehicle.
Disconnect the negative cable (-) from the battery when electric welding.
When two or more persons are working together, make sure that each is working in safe conditions.
Be sure that all the mechanics working on any one vehicle are thoroughly briefed as what each will be
doing, and insure that one mechanic is responsible for insuring that all safety related items, such as tight-
ening torques, are properly considered.
WARNING
WARNING

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WARNING
Automatic Switch-on Device version
optional
REFITTING COMPONENTS
Never use a circlip twice. When a circlip is removed, it must be replaced with a new one. When assembling
a new circlip, be careful not to stretch its ends more than strictly necessary to place it on the shaft. After
installing a circlip, make sure that it is completely and firmly inserted in its seat.
Do not used compressed air to clean bearings.
NOTE 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. Use proprietary assembly lubricants when appropriate.
When tightening nuts and bolts, start with the larger diameter or inner ones and proceed in diagonal order. Tighten
them in gradual steps before applying the final tightening torque.
Always replace all gaskets, circlips, snap rings and O-rings. Replace self-locking nuts if the finger torque allows the
nut to be run on to its matching bolt more than one half turn. Replace the pins, screws and bolts if they are nicked,
cracked, or if there is any sing of thread damage.
Thoroughly clean all mating surfaces before reassembly.
Apply a thin film of lithium-based grease to oil seal rims.
Always replace oil seals. Upon reassembly, apply a thin film of lithium-based grease to the sealing lip of all oil seals
before it is assembled over its matching shaft.
Check to make sure that each component has been fitted properly.
After carrying out repairs or routine servicing, go through the pre-ride checklist thoroughly before riding the motor-
cycle or allowing it to be ridden. Take a trial run in a parking lot or other low traffic area before returning the motor-
cycle to its owner.
USING THE MANUAL
HOW TO USE THE MANUAL:
This manual is divided up into chapters. Each chapter is based on a category of main components. Refer to the
MAIN CONTENTS list.
Unless expressly stated otherwise, follow the disassembly steps in reverse order when reassembling units. The
terms “right” and “left” are intended as the rider’s right and left when sitting in the normal riding position. Consult
the “USE AND MAINTENANCE” handbook for information on the normal use and servicing of the motorcycle.
In this manual, variants from the standard version are marked with the following symbols:
BEFORE DISASSEMBLY
Remove all dirt, mud, dust and foreign bodies from the motorcycle before removing any components.
When specified, use the service tools specially designed for this motorcycle.
DISASSEMBLY OF COMPONENTS
Never loosen and/or tighten nuts and bolts with pliers or other similar tools: always use a proper wrench.
Mark the positions of all unions and connections (hoses, wires, etc.) before disconnecting them with clearly distin-
guishable marks.
Each component must be clearly marked so that it can be identified for refitting.
Clean and wash each removed component with fire-proof solvent.
Paired components must be kept together, as they become “matched” after normal wear. Some paired components
must either be used together or both replaced.
Keep away from heat sources.

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NOTES

General information
General information RS 50
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1

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1-2
POSITION OF SERIAL NUMBERS
These numbers are required for vehicle registration.
NOTE The alteration of the identification numbers is
an offence, punishable with criminal and administra-
tive sanctions. In particular, the alteration of the frame
number will result in the immediate invalidation of the
warranty.
A
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.
B
INFORMATION CONTAINED IN THE MOTORCYCLE
IDENTIFICATION NUMBER
DIGIT MEANING
1) Manufacturer’s identification alphanumeric code.
2) Motorcycle type.
3) Model.
4) Country for which the motorcycle is intended.
5) Production year.
6) Assembling factory designation
(N = NOALE- VE- ,
S = SCORZÉ -VE- ,
0 = NOT SPECIFIED).
7) Sequential serial number.
✩ZD4PG0000X0000000✩
123456 7

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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
Gasoline is extremely flammable and in some
conditions can become explosive.
Therefore, it is necessary to refuel and carry out
maintenance operations involving the fuel system
in a well-ventilated area with the engine off.
Do not refuel or do any maintenance on the fuel
system with the engine running.
Do not smoke while refueling or near fuel vapors.
Never allow any portion of the fuel system to come
in contact with open flames, sparks or other heat
sources.
Be careful to avoid spilling fuel when you are
refueling. Spilled fuel couid ignite when it contacts
hot engine or exhaust system surfaces.
If you accidentally spill some fuel, make sure that
it is wiped up or completely evaporated before
starting the vehicle.
Since gasoline expands in the fuel tank when the
vehicle is sitting in the open sun, never fill the tank
completely to the brim.
Leave at least one inch of expansion space.
Avoid any contact of the fuel with your skin, and
avoid inhalation of fuel vapors.
Do not ever attempt to siphon fuel from one con-
tainer to another using your mouth as suction for a
siphon hose.
Gasoline is poisonous and carcinogenic and
contains chemical substances that cause birth
defects and other reproductive problems.
If gasoline should be accidentally spilt on the skin
or clothes, immediately wash it off with soap and
water and change clothes.
Should you accidentally spill gasoline in your
eyes, flush with a large quantity of water and
immediately contact a health professional.
Should you accidentally get gasoline into your
mouth, do not induce vomiting.
Drink a large quantity of milk or clear water and
immediately contact a health professional.
WARNING

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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
only destroy the vehicle but also could do serious
property damage to surrounding property and
cause serious injuries or even death.
ALWAYS KEEP GASOLINE AWAY FROM CHIL-
DREN.
DISPOSE OF UNWANTED GASOLINE PROPERLY,
DO NOT DUMP IT INTO STORM SEWERS OR INTO
A SINK OR TOILET.
Before opening the fuel filler cap, if necessary,
clean the it cap and the part around it with a clean
cloth. Prevent any foreign material from getting
into the fuel tank, this could lead to serious en-
gine damage.
If you use any container or funnel for refueling,
make sure that it is perfectly clean.
Any foreign matter getting into the fuel tank may
lead to severe damage.
CAUTION
Do not add any additives or other substances to
the gasoline.
Do not refuel the tank completely; the fuel should
never be touching the rim of filler cap seat hale.
After refueling, replace the fuel filler cap (1) in the
correct position and make sure that it is properly
closed.
Use only unleaded gasoline minimum octane rating
(M+R)/2 method 90.
FUEL TANK CAPACITY
(reserve included): 13l (3.4 gal).
TANK RESERVE: 2.6 l (0.69 gal).
WARNING 1

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LUBRICANTS
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.
Use latex gloves for the maintenance operations
that require contact with used oil.
Used oil may cause skin cancer if repeatedly lefl
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 han-
dling used oil.
KEEP OIL AWAY FROM CHILDREN.
DISPOSE OF OIL PROPERLY.
Be very careful when putting oil in your vehicle
not to spill oil.
Clean up any oil spilled immediately because oil
can damage the finish of your vehicle.
Also, oil on the tires creates an extremely slippery
and therefore dangerous situation.
In case of lubricant leakage do not ride the ve-
hicle, but check to determine the cause of the
leakage and repair it.
WARNING
CAUTION
ENGINE OIL
If the engine oil pressure warning light LED “ ” (1)
remains on (when the engine is running), or if it
comes on during the normal running of the engine,
this means that the oil system is not developing
sufficient pressure.
Failure to heed this warning can lead to engine
seizure, upset, and serious injury or even death.
Perform these maintenance operations at one-half
of the specified intervals, if the vehicle is often
used in rainy or very dusty conditions, or on un-
paved roads.
As an alternative to the recommended oil, it is possible
to use high-quality oils with characteristics in compliance
with or superior to the ISO-L-ETC ++, A.P.I. TC ++
specifications.
WARNING
CAUTION 1

General information RS 50
Release 00 2001-03
ch. 1
1-6
FORK OIL
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).
The two products can be used in different percent-
ages until the desired response is obtained.
One of the properties of F.A. and F. A. 5W or
F. A. 20W fork oil (as an alternative FORK 5W
or FORK 20W) is that their viscosity changes
little with changes in temperature and their damp-
ing response therefore remains constant.
WARNING
COOLANT
Do not use the vehicle if the coolant is below the
minimum prescribed level.
Before setting off, and every 2,000 km (1,228 mi),
check the level of the coolant, see (CHECKING AND
TOPPING UP); renew the coolant every two years, see
(CHANGING THE COOLANT).
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 attention.
Coolant is also very dangerous to your skin and eyes.
Should you accidentally get coolant on your cloth-
ing or skin, change clothes immediately.
Wash coolant from your skin with hot water and
soap.
Should you get coolant in your eyes, flush with
plenty of cool water and seek professional medical
help at once.
Should someone swallow coolant accidentally,
induce vomiting, rinse mouth with water, and
immediately seek professional medical attention.
DISPOSE OF THE COOLANT PROPERLY.
CAUTION
WARNING

General information RS 50
ch. 1
Release 00 2001-03 1-7
1
BE SURE TO KEEP THE DRAINED COOLANT
AWAY FROM CHILDREN AND PETS.
IT IS SWEET TASTING, AS WELLAS 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. It is flammable, and can
emit invisible, noxious fumes.
Always wear rubber or latex gloves when servic-
ing the cooling system.
The coolant is made up of 50% water and 50%
antifreeze.
This mixture is ideal for most running temperatures
and ensures good protection against corrosion.
It is advisable to keep the same mixture also in the hot
season, since in this way losses due to evaporation
are reduced and it is not necessary to top up very
frequently.
The mineral salt deposits left in the radiator by evapo-
rated water are thus reduced and the efficiency of the
cooling system remains unchanged.
If the outdoor temperature is below 0°C, check the
cooling circuit frequently and if necessary increase the
antifreeze concentration (up to maximum 60%).
Use only distilled water when topping off the
cooling system. This will reduce damage to the
engine.
The coolant is very hot.
Do not remove the filler cap (1) when the engine is
hot since the coolant is under pressure and it will
splash out violently.
If it gets in contact with the skin or with your
clothing, it may cause severe burns.
CAUTION
WARNING
Be aware of the risk of burns from the coolant.
Check the coolant level and top up the expansion
tank only after the engine has thoroughly cooled.
Do not use your fingers or any other object to
check if there is enough coolant.
WARNING
1

General information RS 50
Release 00 2001-03
ch. 1
1-8
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
°C (°F) Coolant % of volume
-20°(-4°)
-30°(-22°)
-40°(-40°)
35
45
55
NOTE The characteristics of the various antifreeze liquids are different.
Be sure to read the label on the product to learn the degree of protection it guarantees.
Use only antifreeze and anticorrosive without nitrite in order to ensure protection at least -35°C.
GEARBOX OIL
Gearbox oil can cause serious skin damage if handled on a daily basis over a long period of time.
You are advised to wash your hands thoroughly after handling the oil.
Do not dispose of the oil in drains, water courses or the soil.
Take the oil to (or have it collected by) the nearest used oil disposal agency or the supplier.
You are advised to wear rubber gloves when carrying out maintenance work.
Change the gearbox oil after the first 500 km (312 miles) and then every 8000 km (5000 miles) (*), see (CHANG-
ING THE GEARBOX OILAND THE ENGINE OIL FILTER).
2 STROKE OIL
2 stroke oil can cause serious skin damage if handled on a daily basis over a long period of time.
You are advised to wash your hands thoroughly after handling the oil.
Do not dispose of the oil in drains, water courses or the soil.
Take the oil to (or have it collected by) the nearest used oil disposal agency or the supplier.
You are advised to wear rubber gloves when carrying out maintenance work.
BRAKE FLUID
NOTE This motorcycle has front and rear disc brakes, with separate hydraulic circuits.
The following information refers to a single braking system, but is applicable to both.
Brake fluid can cause irritation if it comes into contact with the skin or eyes.
Thoroughly wash any parts of the body that come into contact with the fluid and contact an eye specialist
or doctor if the fluid comes into contact with the eyes.
DO NOT DISPOSE OF THE FLUID IN DRAINS, WATER COURSES OR THE SOIL.
KEEP OUT OF REACH OF CHILDREN.
Avoid splashing brake fluid on the plastic or painted parts of the motorcycle, as it will cause damage.
Check the brake fluid level every 4000 km (2500 miles), (CHECKING AND TOPPING UP THE FRONT BRAKE
FLUID) and (CHECKING AND TOPPING UP THE REAR BRAKE FLUID); change the fluid every year,
(CHANGING THE FRONT BRAKE FLUID) and (CHANGING THE REAR BRAKE FLUID).
CAUTION
CAUTION
CAUTION
CAUTION

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ch. 1
Release 00 2001-03 1-9
1
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.
Sudden variations in the play or looseness of the brake levers are caused by problems in the hydraulic
circuits.
Check very carefully to ensure that there is no oil or grease on the brake discs and friction gaskets, espe-
cially after servicing or inspections.
Check that the brake hoses are not twisted or worn.
Make sure no water or dust gets into the circuit accidentally.
You are advised to wear rubber gloves when working on the hydraulic circuit.
CARBON MONOXIDE
If a servicing operation has to be carried out with the engine running, make sure this is done in the open air or in a
well-ventilated area.
Never run the engine in enclosed spaces. If you have to work in an enclosed space, use an exhaust fume extrac-
tion system.
Exhaust fumes contain carbon monoxide, a poisonous gas that can cause loss of consciousness and
death.
Run the engine in the open air or, if you have to work in an enclosed space, use an exhaust fume extraction sys-
tem.
COMPONENTS AT HIGH TEMPERATURES
The engine and the exhaust system components get very hot and stay hot for a certain time after the
engine has been switched off.
Wear heat-proof gloves if you have to handle these components, or else wait until the engine and exhaust
system have cooled down.
RUNNING-IN RULES
After the motorcycle has been operated for 500 km (300 mi), perform the checking operation shown in the
column “After running-in” of the REGULAR SERVICE INTERVALS CHART.
Failure to heed this warning can lead to damage to your motorcycle, engine seizure or other malfunction which
could cause an upset and lead to serious injury or even death.
The internal parts of the engine and transmission must be properly run-in to ensure their long life and dependable
operation.
If possible, while breaking in your motorcycle, ride on hilly roads and/or roads with many curves so that the engine
and transmission undergo lots of speed changes. It is also important that, during the run-in period, the suspension
and brakes be treated gently to allow the mating parts to bed.
Therefore, avoid hard braking, high speeds or very bumpy roads during the break in period.
0- 100 km (0- 62 mi)
Apply the brakes gently, avoiding sudden or prolonged braking.
0- 300 km (0- 187 mi)
Open the throttle no more than one-half way for extended periods.
300- 500 km (187- 312 mi)
Open the throttle no more than three-quarters for extended periods.
CAUTION
CAUTION
WARNING