APRILIA RS 50 Workshop Manual
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APRILIA RS 50 Workshop Manual

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RS 50
1024 Y

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Summary of Contents for APRILIA RS 50

  • Page 1 Workshop manual RS 50 1024 Y...
  • Page 2 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 Periodic Maintenance qualified mechanics. Many concepts have been inten- tionally omitted as they were considered superfluous.

  • Page 3: Table Of Contents

    RS 50 TABLE OF CONTENTS Chapter 1 LOCATION OF SERIAL NUMBERS ...................... 1-2 NOTES ON FUEL, LUBRICANTS, COOLANT AND OTHER ITEMS ............ 1-2 RUNNING-IN RULES ..........................1-6 SPARE PARTS ............................1-7 TECHNICAL DATA ..........................1-7 LUBRICANT CHART ..........................1-9 SPECIAL TOOLS OPT ........................
  • Page 4 RS 50 Chapter 3 ENGINE COMPONENTS THAT CAN BE REMOVED WITHOUT REMOVING THE ENGINE FROM THE FRAME ..............3-2 REMOVING THE ENGINE ASSEMBLY FROM THE FRAME .............. 3-3 Chapter 4 FUEL TANK ............................4-2 MAINTENANCE ............................ 4-3 CHECKING THE FUEL SUPPLY ......................4-3 REMOVING THE FUEL COCK ......................
  • Page 5 RS 50 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 ....................
  • Page 6 RS 50 REAR WHEEL ............................ 7-58 REMOVING THE REAR WHEEL ASSEMBLY ..................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 .....................
  • Page 7 RS 50 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!
  • Page 8 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.
  • Page 9 RS 50 NOTES Release 00 2001-01...
  • Page 10 General Information RS 50 General Information chap. 1 Release 00 2001-1...

  • Page 11: Location Of Serial Numbers

    General Information RS 50 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.
  • Page 12 General Information RS 50 TRANSMISSION OIL WARNING 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.
  • Page 13 General Information RS 50 WARNING 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.
  • Page 14 General Information RS 50 COOLANT WARNING 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.

  • Page 15: Running-In Rules

    General Information RS 50 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.

  • Page 16: Spare Parts

    General Information RS 50 SPARE PARTS Only use Genuine aprilia Spares. All Genuine aprilia Spares are high-quality parts specially designed and manufactured for aprilia vehicles. CAUTION Using NON-genuine aprilia spares may result in damage and poor performance. TECHNICAL DATA DIMENSIONS Max.
  • Page 17 General Information RS 50 GEAR RATIOS Ratio 2 16/33 = 1:2.062 Secondary Total ratio 1:28.677 Ratio 3 19/29 = 1:1.526 Secondary Total ratio 1:21.222 Ratio 4 22/27 = 1:1.227 Secondary Total ratio 1:17.064 Ratio 5 24/25 = 1:1.042 Secondary Total ratio 1:14.483...

  • Page 18: Lubricant Chart

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

  • Page 19: Special Tools Opt

    General Information RS 50 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.
  • Page 20 General Information RS 50 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.

  • Page 21: General Specifications For Tightening Torques

    General Information RS 50 GENERAL SPECIFICATIONS FOR TIGHT- ENING TORQUES The table below shows standard tightening torques for screws and bolts with ISO metric threads. Tightening torques threads Spanners Screw/bolt Nm (Ft-lb) 6 (4.4) 15 (11.1) 30 (22.1) 55 (40.5) 85 (62.7)

  • Page 22: Abbreviations, Symbols, Acronyms

    General Information RS 50 ABBREVIATIONS, SYMBOLS, ACRONYMS = number = metres/second < = is less than = maximum > = is greater than mbar = millibars ≤ ≤ ≤ ≤ ≤ = is less than or equal to = miles ≥...
  • Page 23 General Information RS 50 NOTES 1-14 chap. 1 Release 00 2001-1...
  • Page 24 Periodic Maintenance Operations RS 50 Periodic Maintenance Operations chap. 2 Release 00 2000-11...
  • Page 25 Periodic Maintenance Operations RS 50 This section describes the operations to be performed periodically when servicing the main vehicle compo- nents. CAUTION Before performing any servicing or checks, switch off the engine, remove the key, allow the engine and the exhaust system to cool down, and if possible lift the vehicle on solid level flooring using specific equipment.
  • Page 26 The above operations must be performed at shorter intervals if the vehicle is used in rainy or dusty areas, or on rough roads. We recommend having the operations marked with a ‘d’ ONLY by an Official aprilia Dealer. u = user d = dealer chap.

  • Page 27: Chapter 2 Lubricating Points

    Periodic Maintenance Operations RS 50 LUBRICATING POINTS KEY TO LUBRICATION CHART 1) Throttle twist grip Proper lubrication is a key factor in ensuring smooth 2) Throttle cable operation and long life of the vehicle. 3) Brake lever pin 4) Speedometer cable...

  • Page 28: Instruments And Indicators

    Periodic Maintenance Operations RS 50 ARRANGEMENT OF THE INSTRUMENTS / CONTROLS 1) Ignition switch/steering lock ( 2) Direction indicator switch ( 3) Horn push button ( ) 4) Dimmer switch ( 5) High beam signalling push button ( ) 6) Clutch lever...

  • Page 29: Battery

    Periodic Maintenance Operations RS 50 BATTERY Carefully read the section PRECAUTIONS AND GENERAL INFORMATION There are two types of batteries on the market: - low-maintenance batteries, in which the cells are stoppered by plugs; - maintenance-free batteries, with no plugs and requiring no electrolyte checks or replenishing.
  • Page 30 Periodic Maintenance Operations RS 50 IMPORTANT Check the battery voltage with a portable multimeter. If the voltage is less than 12 V, the battery needs to be recharged. CHECKING AND CLEANING THE TERMINALS Carefully read (BATTERY). Remove the rider saddle, see p. 50 (REMOVING THE RIDER SADDLE).
  • Page 31 Periodic Maintenance Operations RS 50 CHECKING THE ELECTROLYTE LEVEL Carefully read (BATTERY). To check the electrolyte level, proceed as follows: Remove the battery (REMOVING THE BATTERY). Make sure that the fluid level is included between the two “MIN” and “MAX” notches stamped on the battery side.

  • Page 32: Long Battery Inactivity

    Periodic Maintenance Operations RS 50 CAUTION After disconnecting the battery charger, wait 5-10 minutes before reinstalling the battery as the battery continues to release gases for a short time. LONG BATTERY INACTIVITY Read through the paragraph BATTERY. Whenever the vehicle remains unused for longer than 15 days, the battery needs to be recharged in order to avoid sulphation (RECHARGING THE BATTERY).
  • Page 33 Periodic Maintenance Operations RS 50 Energetically blow some air, in order to prevent the 0.6 ÷ 0.7 mm removed residues from getting into the engine. (0.024 ÷ 0.026 in) If the spark plug has crackings on the insulating material, corroded electrodes or excessive deposits, it must be changed.

  • Page 34: Air Cleaner

    Periodic Maintenance Operations RS 50 AIR CLEANER WARNING Do not use petrol or inflammable solvents to wash the air cleaner, in order to avoid fires or explo- sions. Carefully read the PERIODIC MAINTENANCE SCHEDULE. Check the conditions of the air cleaner and clean it monthly or every 4000 km (2500 mi), depending on the conditions in which the vehicle is used.

  • Page 35: Idling Adjustment

    Periodic Maintenance Operations RS 50 ADJUSTING THE ACCELERATOR CONTROL Carefully read the PERIODIC MAINTENANCE SCHEDULE. The idle stroke of the throttle grip must be 2 ÷ 3 mm (0.079 ÷ 0.118 in), measured on the edge of the grip itself.

  • Page 36: Controls On The Carburettor

    Periodic Maintenance Operations RS 50 CONTROLS ON THE CARBURETTOR COLD START LEVER The cold start lever (1) is positioned on the right side of the carburettor. It can be reached from above through the opening positioned between the fairing and the frame.
  • Page 37 Periodic Maintenance Operations RS 50 WARNING Danger of fall or overturning. When the vehicle is straightened from the parking position to the driving position, the stand goes automatically up. Keep the vehicle in vertical position, with the two wheels resting on the ground.

  • Page 38: Changing The Transmission Oil

    Periodic Maintenance Operations RS 50 CHANGING THE TRANSMISSION OIL Read through the paragraph TRANSMISSION OIL and the PERIODIC MAINTENANCE SCHEDULE. Check the transmission oil level every 4000 km (2500 mi), change it after the first 500 km (312 mi) and successively every 8000 km (5000 mi).
  • Page 39 Periodic Maintenance Operations RS 50 Keep the vehicle in vertical position, with the two wheels resting on the ground. Put a container (1) with at least 900 cm (55 cu.in capacity in correspondence with the drain plug (2). Unscrew and remove the drain plug (2).

  • Page 40: Mixer Oil Reservoir

    Periodic Maintenance Operations RS 50 2 STROKE OIL TANK Top up the 2 stroke oil tank every 500 km (312 mi). The vehicle is provided with a separate mixer that ensures the mixing of petrol and oil for the engine lubrication, see (LUBRICANT CHART).

  • Page 41: Coolant

    Periodic Maintenance Operations RS 50 Remove the two screws (1) shown in the figure and take off the oil pump cover. Prepare a container with a capacity of over of 2 l. Remove clamp (2) and then disconnect oil feed pipe (3) and drain all the oil from the tank into the con- tainer.
  • Page 42 Periodic Maintenance Operations RS 50 WARNING The coolant is noxious: do not swallow it; if the coolant gets in contact with the skin or the eyes, it can cause serious irritations. If the coolant gets in contact with your skin or eyes, rinse with plenty of water and consult a doctor.
  • Page 43 Periodic Maintenance Operations RS 50 CHECKING AND TOPPING UP Check the coolant level and top up the expansion tank with cold engine. Stop the engine and wait until it has cooled down. NOTE Position the vehicle on firm and flat ground.
  • Page 44 Periodic Maintenance Operations RS 50 RENEWING THE COOLANT Read through the paragraphs PRECAUTIONS AND GENERAL INFORMATION and COOLANT. Renew the coolant every two years. Remove the right-hand side fairing (REMOVING THE SIDE FAIRINGS). Place a container with a capacity of over 1 l (2.1 gal) under drain screw (1).
  • Page 45 Periodic Maintenance Operations RS 50 BRAKE FLUID-recommendations NOTE This vehicle is provided with front and rear disc brakes, with separate hydraulic circuits. The following information refers to a single braking system, but is valid for both. WARNING Sudden resistance or clearance problems on the brake lever may be due to troubles in the hydraulic system.

  • Page 46: Front Brake

    Periodic Maintenance Operations RS 50 WARNING This vehicle is provided with front and rear hydraulic disc brakes. When the disc pads wear out, the level of the fluid decreases to automatically compensate for their wear. The front brake fluid tank is positioned on the right part of the handlebar, near the front brake lever coupling.
  • Page 47 Periodic Maintenance Operations RS 50 CAUTION When topping up, never exceed the “MAX” level. It is advisable to top up until reaching the “MAX” level only with new pads. When the disc pads wear out, the level of the fluid decreases progressively to compensate for their wear.

  • Page 48: Rear Brake

    Periodic Maintenance Operations RS 50 REAR BRAKE CHECKING NOTE Position the vehicle on firm and flat ground. WARNING Danger of fall or overturning. When the vehicle is straightened from the parking position to the driving position, the stand goes automatically up.

  • Page 49: Renewing The Front Brake Fluid

    Periodic Maintenance Operations RS 50 CAUTION It is advisable to top up until reaching the “MAX” level only with new pads. When the disc pads wear out, the level of the fluid decreases progressively to compensate for their wear. Do not reach the “MAX” level with worn out pads, since this will cause a fluid outflow when the pads are changed.

  • Page 50: Renewing The Rear Brake Fluid

    Periodic Maintenance Operations RS 50 Watch the outflow of the fluid on reservoir (2) and tighten bleeder (1) before the reservoir has emptied. Top up by pouring fluid into reservoir (2) (CHECKING AND RESTORING THE BRAKE FLUID LEVEL). Loosen bleeder (1) of about a half turn.

  • Page 51: Air-Bleeding The Braking Systems

    Periodic Maintenance Operations RS 50 Watch the outflow of the fluid on reservoir (2) and tighten bleeder (1) before the reservoir has emptied. Top up by pouring fluid into reservoir (2) (CHECKING AND RESTORING THE BRAKE FLUID LEVEL). Loosen bleeder (1) of about a half turn.
  • Page 52 Periodic Maintenance Operations RS 50 CAUTION To avoid personal injury and damage to the vehi- cle, it is absolutely essential that, after refitting the brakes and restoring the braking system to the normal operating conditions, the hydraulic system should be bled of the air it contains by following the procedure described below.

  • Page 53: Adjusting The Rear Brake

    Periodic Maintenance Operations RS 50 ADJUSTING THE REAR BRAKE The brake pedal is positioned ergonomically during the assembly of the vehicle. If necessary, it is possible to adjust the height of the brake pedal: Position the vehicle on the stand.

  • Page 54: Adjusting The Clutch

    Periodic Maintenance Operations RS 50 ADJUSTING THE CLUTCH Adjust the clutch and if the engine stops or tends to advance when the clutch lever is pulled and the gears are engaged, or if the clutch slips causing a delay in the acceleration in comparison with the engine speed.

  • Page 55: Steering

    Periodic Maintenance Operations RS 50 STEERING Read through the section PRECAUTIONS AND GENERAL INFORMATION. For ease of handling, the steering is equipped with rolling bearings. The steering must be properly adjusted in order to ensure smooth handlebar rotation and riding safety.

  • Page 56: Drive Chain

    Periodic Maintenance Operations RS 50 Reposition fork upper plate (5). Place washer (2) on the head tube and then screw in and tighten head tube plug (1). Tightening torque for head tube plug (1): 80 Nm (8.0 kgm) [59 ft-lb] Screw in and tighten screws (3).
  • Page 57 Periodic Maintenance Operations RS 50 CAUTION Incorrect maintenance may cause the untimely wear of the chain and/or damages to the pinion and/or the crown. Carry out the maintenance operations more frequently if you use the vehicle in difficult condi- tions or on dusty and/or muddy roads.
  • Page 58 Periodic Maintenance Operations RS 50 ADJUSTMENT NOTE To adjust the chain it is necessary to use the appropriate rear support stand If after the check it is necessary to adjust the chain tension, proceed as follows: Position the vehicle on the appropriate rear support...

  • Page 59: Periodic Maintenance And Adjustments

    Periodic Maintenance Operations RS 50 CLEANING AND LUBRICATION CAUTION Carry out the adjustment, lubrication, cleaning and change of the chain with great care. Lubricate the chain every 500 km (312 mi) or when- ever necessary. Lubricate the chain with spray grease for chains or with SAE 80W-90 oil.
  • Page 60 Periodic Maintenance Operations RS 50 WARNING Periodically check the tyre inflating pressures at room temperature. Hot tyres provide incorrect measurements. In particular, measure the tyre pressures before and after covering long distances. If the inflating pressure is excessive, vibration from uneven road surfaces is not dampened and is transmitted to the handlebars.

  • Page 61: Fuel Lines

    Tyres having dimensions other than those speci- fied may alter the geometry of the vehicle and reduce manoeuvrability and riding safety. Only fit the tyres originally chosen by aprilia (refer to the TECHNICAL DATA tables). FUEL LINES Read through the paragraph FUEL.

  • Page 62: Mixer Oil Lines

    Periodic Maintenance Operations RS 50 MIXER OIL LINES Check mixer oil lines (2) every 4,000 km (2,500 mi) or 8 months. Replace them every 4 years. Replace the mixer oil lines if they show signs of wear, cracks, etc. BULBS CAUTION Carefully read (MAINTENANCE).
  • Page 63 Periodic Maintenance Operations RS 50 CHANGING PARKING LIGHT BULB CAUTION To extract the bulb socket, do not pull the electric wires. Working on the rear side of the front part of the fairing, seize the bulb socket (1), pull it and remove it from its seat.
  • Page 64 Periodic Maintenance Operations RS 50 CHANGING LOW BEAM BULB NOTE Extract the bulb sockets one by one, in such a way as to avoid positioning them incorrectly during the reassembly. If the bulb sockets must be removed at the same time, take care to reassemble them in the correct position.
  • Page 65 Periodic Maintenance Operations RS 50 CHANGING THE REAR LIGHT BULB Carefully read (BULBS). NOTE Before changing a bulb, check the fuse, see (CHANGING THE FUSE) and the effective operation of the stoplight switches, see (CHECKING THE SWITCHES). Position the vehicle on the stand.

  • Page 66: Tightening Of Bolts And Nuts

    Periodic Maintenance Operations RS 50 TIGHTENING OF BOLTS AND NUTS Read through the section PRECAUTIONS AND GENERAL INFORMATION. Check the bolts and nuts after the first 1,500 km (900 mi), and then every 7,500 km (4,500 mi) or 8 months.

  • Page 67: Fastenings

    Periodic Maintenance Operations RS 50 FASTENINGS Check and if necessary tighten the fastenings after the first 1,000 km (625 mi), and then every 7,500 km (4,500 mi) or 8 months. WARNING The fastenings shown in the table below must be tightened using a torque spanner and, where appropriate, ®...
  • Page 68 Periodic Maintenance Operations RS 50 REAR SUSPENSION Description Q.ty Screw/nut Nm (Ft-lb) Code Shock absorber to swing arm CSH M10x60 48 (35.4) 8150049 Shock absorber to saddle support CSH M10x60 48 (35.4) 8150049 ENGINE Description Q.ty Screw/nut Nm (Ft-lb) Code Gear lever pin part no.
  • Page 69 Periodic Maintenance Operations RS 50 REAR WHEEL Description Q.ty Screw/nut Nm (Ft-lb) Code Rear brake lever pin part no. 5058 12 (8.8) 8121149 Rear brake pump HH FL. M6x20 10 (7.4) 8152279 Brake lever adjuster HH FL. M5x16 5 (3.7)
  • Page 70 Periodic Maintenance Operations RS 50 BODYWORK Description Q.ty Screw/nut Nm (Ft-lb) Kgm Code Reflector on front mudguard M4 nut 3 (2.2) 8150204 Front mudguard to stiffening plate HH FL. M6x16 7 (5.2) 8152278 Front mudguard to fork FSH M5x12 5 (3.7)
  • Page 71 Periodic Maintenance Operations RS 50 NOTES 2-48 chap. 2 Release 00 2000-11...
  • Page 72 Engine RS 50 Engine chap. 3 Release 00 2000-11...

  • Page 73: Engine Components That Can Be Removed Without Removing The Engine From The Frame

    Engine RS 50 ENGINE COMPONENTS THAT CAN BE REMOVED WITHOUT REMOVING THE ENGINE FROM THE FRAME Read through the section PRECAUTIONS AND GENERAL INFORMATION. The following parts can be removed and refitted without removing the engine from the frame. WARNING This chapter lists the different procedures sequentially.

  • Page 74: Removing The Engine Assembly From The Frame

    Engine RS 50 REMOVING THE ENGINE ASSEMBLY FROM THE FRAME WARNING Read through the section PRECAUTIONS AND GENERAL INFORMATION. WARNING The removal of the engine is a very complex operation. Therefore, before proceeding, it is essential to thoroughly inspect the vehicle.
  • Page 75 Engine RS 50 Unscrew ring (1) and remove tachometer cable (2). Remove protective hood (3). Loosen nut (4) by turning it in. Turn adjuster (5) to slacken the clutch cable. Push clutch lever (6) on the engine and disconnect clutch control cable (7).
  • Page 76 Engine RS 50 Disconnect oil pump control cable (10) and remove the cable along with cable guide tube (11). After removing the oil pipe rubber, loosen and remove clamp (12) and then remove oil feed pipe (13). IMPORTANT To prevent the oil from coming out, immediately stopper oil feed pipe (13) using a screw of suitable diameter.
  • Page 77 Engine RS 50 WARNING Disengage all the cables and pipes from the clamps along their paths. Have new clamps ready for refitting. Close all openings on the engine, tubes and sleeves so as to prevent foreign bodies from getting in.
  • Page 78 Engine RS 50 Unscrew and remove the two screws (36) and the screw that supports the bracket at the back of the motor. Remove starter motor (37). Remove engine cradle (38) (REMOVING THE EN- GINE CRADLE). Prepare a hoist and sling belts.
  • Page 79 Engine RS 50 Remove the two screws (39) fastening the engine to the frame and gather the related washers and the self- locking nuts on the opposite side. CAUTION The engine is now completely unfastened. Handle it with great caution, paying particular attention to the fingers and limbs.
  • Page 80 Fuel System RS 50 Fuel System chap. 4 Release 00 2000-11...

  • Page 81: Chapter 4 Fuel Tank

    Fuel System RS 50 FUEL TANK The fuel tank is fitted with a cap and a cock. The cock shown in the figure has three positions (OFF, ON and RES) which can be selected by means of the cock lever.

  • Page 82: Maintenance

    Fuel System RS 50 Read through the section PRECAUTIONS AND GENERAL INFORMATION and the paragraph FUEL. CAUTION Fuel fumes are harmful. Before beginning, ensure that the place where the operation is to be carried out is adequately venti- lated. Prevent the fuel from coming into contact with the skin.

  • Page 83: Removing The Fuel Cock

    Fuel System RS 50 REMOVING THE FUEL COCK Lift the fuel tank (LIFTING THE FUEL TANK). Remove screws (1) and pull out fuel cock assembly (2). Position fuel cock (2) under the tank and secure it by means of screws (1).
  • Page 84 Fuel System RS 50 1) Air valve 12) Fuel filter 2) Throttle valve 13) Air valve control shaft 3) Main jet 14) Needle 4) Float 15) Float pin 5) Deflector tube kit 16) Sleeve clamping screw 6) Gaskets 17) Float chamber...

  • Page 85: Removing The Mixer Oil Reservoir

    Fuel System RS 50 REMOVING THE MIXER OIL RESERVOIR Read through the section PRECAUTIONS AND GENERAL INFORMATION. Remove the rider and passenger saddles (REMOV- ING THE RIDER AND PASSENGER SADDLES). Remove the fuel tank (REMOVING THE FUEL TANK). Remove the rear fairing (REMOVING THE REAR FAIRING).
  • Page 86 Fuel System RS 50 Remove clamp (3) and pull out pipe (4) delivering oil to the pump. To remove mixer oil reservoir (5), rotate it while pulling it towards the rear part of the frame. Replace the mixer oil reservoir in its seat and secure it to the frame by means of flanged screws (1).
  • Page 87 Fuel System RS 50 NOTES chap. 4 Release 00 2000-11...
  • Page 88 Cooling System RS 50 Cooling System chap. 5 Release 00 2000-11...

  • Page 89: Removing The Radiator

    Cooling System RS 50 REMOVING THE RADIATOR Read through the section PRECAUTIONS AND GENERAL INFORMATION and the paragraph COOLANT. Remove the right-hand side panel (REMOVING THE SIDE FAIRINGS). Remove the lower fairing tip (REMOVING THE FAIRING BULGES). Drain all the coolant from the circuit (RENEWING THE COOLANT).

  • Page 90: Removing The Filler Cap

    Cooling System RS 50 Close the manifold openings so as to prevent foreign bodies from getting in. WARNING IMPORTANT If rubbers (9) are damaged, replace them. WARNING Use a compressed air jet to remove dirt, foreign bodies, etc. sticking to the radiator fins.
  • Page 91 Cooling System RS 50 NOTES chap. 5 Release 00 2000-11...
  • Page 92 Electrical Equipment RS 50 Electrical Equipment chap. 6 Release 00 2000-11...

  • Page 93: Chapter 6 Introduction

    Electrical Equipment RS 50 INTRODUCTION The following indications help to clarify the con- tent of this section. IMPORTANT The identification numbers appearing in the specific wiring diagrams correspond to those shown in the general wiring diagram. RECOMMENDED EQUIPMENT Multimeter Battery electrolyte densimeter Stroboscopic gun for two-stroke engines, 10,000 rpm 0 ÷...
  • Page 94 Electrical Equipment RS 50 WIRING DIAGRAM LOCK PASSING Bi/N Bi/N Bi/R Bi/R KEY TO GENERAL WIRING DIAGRAM Left-hand turn indicator warning light Generator High beam warning light Ignition coil Voltage regulator Low beam warning light Mixer oil reserve warning light...

  • Page 95: Location Of Components

    Electrical Equipment RS 50 LOCATION OF COMPONENTS 21 23 25 26 Generator Left-hand turn indicator warning light Ignition coil High beam warning light Voltage regulator Low beam warning light Rectifier Mixer oil reserve warning light Battery Neutral indicator Start relay...

  • Page 96: Ignition Circuit

    Electrical Equipment RS 50 IGNITION CIRCUIT Refer to the paragraph LOCATION OF COMPO- NENTS. ELECTRICAL DIAGRAM Bi/R Bi/R Generator Transducer Spark plug Ignition switch Right-hand lights switch SPECIFICATIONS Spark plug ........ NGK R BR9ES Spark gap ......... 0.6 ± 0.7 mm (0.02 ± 0.03 in) Spark advance ......
  • Page 97 Electrical Equipment RS 50 If the trouble persists: Check the high-voltage cable. Check the spark plug cap. Check the ignition flywheel (CHECKING THE IGNI- TION FLYWHEEL). Replace the transducer with one that is certainly working. If this solves the problem: Check the ignition switch (CHECKING THE IGNITION SWITCH).

  • Page 98: General Feeding And Recharge Circuit

    Electrical Equipment RS 50 GENERAL FEEDING AND RECHARGE CIRCUIT Refer to the paragraph LOCATION OF COMPO- NENTS. ELECTRICAL DIAGRAM Luci Servizi in D.C. Generator Voltage regulator Rectifier Battery Ignition switch SPECIFICATIONS Generator ............ 105 W a.c. at 6,000 rpm Voltage regulator ..........12 V a.c.
  • Page 99 Electrical Equipment RS 50 TROUBLESHOOTING A. BATTERY DOES NOT STAY CHARGED Check and if necessary replace the fuse. Replace the rectifier. Check the wire connections on the regulator, the flywheel, the battery and the fuse. Check the battery (CHECKING THE BATTERY).

  • Page 100: Starting Circuit

    Electrical Equipment RS 50 CHECKING DATA CHECKING THE GENERATOR Disconnect the yellow wire from the regulator. Start the engine and increase its speed to 6,000 rpm. Using a multimeter as an a.c. voltmeter, check that: voltage between yellow wire and generator earth is greater than 35 V.
  • Page 101 Electrical Equipment RS 50 SPECIFICATIONS Starter motor ........... 12 V - 150 W Brush wear limit ........0.9 mm (0.03 in) Starting relay ..........12 V - 70 A Battery ............12 V - 4 Ah TROUBLESHOOTING A. STARTER MOTOR DOES NOT TURN OR TURNS VERY SLOWLY Check the battery (CHECKING THE BATTERY).
  • Page 102 Electrical Equipment RS 50 CHECKING DATA CHECKING THE STARTING RELAY Disconnect all relay wires. Using a multimeter as an ohmmeter, measure continu- ity between terminals 30 and 87. Correct value: infinite resistance. Power terminal 85 and 86 with a 12 V battery.

  • Page 103: Sensors Circuit

    Electrical Equipment RS 50 SENSORS CIRCUIT Refer to the paragraph LOCATION OF COMPO- NENTS. ELECTRICAL DIAGRAM Locked positive Bi/N Oil reserve sensor Water temperature thermistor Neutral sensor Water temperature indicator Oil reserve warning light Neutral indicator SPECIFICATIONS All-glass warning light bulbs ....12 V - 2 W, W2,1x9,5d...

  • Page 104: Turn Indicators Circuit

    Electrical Equipment RS 50 B. WARNING LIGHT STAYS ON EVEN IF OIL LEVEL IS NORMAL Check the connections of the wires. Check the oil level sensor (CHECKING THE OIL LEVEL SENSOR). CHECKING DATA CHECKING THE OIL LEVEL SENSOR Disconnect the sensor wires and remove the sensor from the reservoir.
  • Page 105 Electrical Equipment RS 50 SPECIFICATIONS Turn indicator bulbs ..... 12 V - 10 W B.A. 15 S Flasher unit ......12 V - 22 W All-glass turn indicator warning light ......12 V - 2 W - W2,1x9,5d TROUBLESHOOTING A. TURN INDICATORS DO NOT WORK Check the bulbs.

  • Page 106: Horn Circuit

    Electrical Equipment RS 50 HORN CIRCUIT Refer to the paragraph LOCATION OF COMPO- NENTS. ELECTRICAL DIAGRAM Locked positive Horn button Horn SPECIFICATIONS Horn ............... 12 V c.c. TROUBLESHOOTING A. HORN GIVES OUT NO SOUND OR AN IRREGU- LAR SOUND Check the battery (CHECKING THE BATTERY).
  • Page 107 Electrical Equipment RS 50 B. HORN SOUNDS CONTINUOUSLY Check the connections of the wires. Check the horn button (CHECKING THE HORN BUTTON). CHECKING DATA CHECKING THE HORN Disconnect the horn and power it directly with a 12 V battery. If necessary, use the specially designed adjuster.

  • Page 108: Stoplights Circuit

    Electrical Equipment RS 50 STOPLIGHTS CIRCUIT Refer to the paragraph LOCATION OF COMPO- NENTS. ELECTRICAL DIAGRAM Locked positive Rear stoplight switch Rear light (rear stoplight bulb) Front stoplight switch SPECIFICATIONS Rear stoplight bulb ........12 V - 21 W TROUBLESHOOTING A.
  • Page 109 Electrical Equipment RS 50 B. STOPLIGHT DOES NOT WORK Check the bulb and the bulb holder. Check the connections of the wires. Check the general feeding circuit. Check the front stoplight switch (CHECKING THE FRONT AND REAR STOPLIGHT SWITCHES). Check the rear stoplight switch (CHECKING THE FRONT AND REAR STOPLIGHT SWITCHES).

  • Page 110: Lighting Circuit

    Electrical Equipment RS 50 LIGHTING CIRCUIT Refer to the paragraph LOCATION OF COMPO- NENTS. ELECTRICAL DIAGRAM From flywheel PASS Regulator Low beam Rear parking light Right-hand lights switch Left-hand lights switch Instrument panel light High beam warning light High beam...

  • Page 111: Lighting Circuit Asd

    Electrical Equipment RS 50 LIGHTING CIRCUIT Refer to the paragraph LOCATION OF COMPO- NENTS. ELECTRICAL DIAGRAM From flywheel PASS Regulator Low beam Rear parking light Right-hand lights switch Left-hand lights switch Instrument panel light High beam warning light High beam...
  • Page 112 Electrical Equipment RS 50 TROUBLESHOOTING A. A BULB DOES NOT WORK Check the bulb. Check if voltage is supplied to the bulb holder termi- nals. Check the wiring connections. B. NO BULBS WORK Check the lights switch. Check the voltage regulator (CHECKING THE VOLT- AGE REGULATOR).
  • Page 113 Electrical Equipment RS 50 COOLANT TEMPERATURE INDICATOR TROUBLESHOOTING A. TEMPERATURE READING IS TOO LOW Check the connections. Check that the green/red cable of the instrument is powered. Check coolant thermistor (1). Check coolant temperature indicator (2). B. TEMPERATURE READING IS TOO HIGH Check the cooling circuit.
  • Page 114 Electrical Equipment RS 50 Connect a pocket multimeter (D) set as an ohmmeter to thermistor (1) (see figure). Immerse thermistor (1) into a container (F) filled with coolant. Dip a thermometer (E) measuring temperatures in the range 0° ± 150° C (32° ± 302° F) into the same container.

  • Page 115: Bulbs

    Electrical Equipment RS 50 BULBS CAUTION Carefully read (MAINTENANCE). Before changing a bulb, turn the ignition switch to position “ ”. Change the bulb wearing clean gloves or using a clean and dry cloth. Do not leave fingerprints on the bulb, since these may cause its overheating and consequent breakage.

  • Page 116: Changing The Low Beam Bulb

    Electrical Equipment RS 50 CHANGING HIGH BEAM BULBS NOTE Extract the bulb sockets one by one, in such a way as to avoid positioning them incorrectly during the reassembly. If the bulb sockets must be removed at the same time, take care to reassemble them in the correct position.

  • Page 117: Changing The Rear Light Bulb

    Electrical Equipment RS 50 CHANGING THE FRONT AND REAR DIRECTION INDICATOR BULBS Carefully read (BULBS). NOTE Before changing a bulb, check the fuse, see (CHANGING THE FUSE). Position the vehicle on the stand. Unscrew and remove the screw (1). NOTE While removing the protection screen, pro- ceed carefully in order not to break the cog.

  • Page 118: Changing The Fuse

    Electrical Equipment RS 50 NOTE Insert the bulb in the bulb socket, making the two bulb pins coincide with the relevant guides on the socket. Correctly install a new bulb (7) of the same type. ADJUSTING THE VERTICAL HEADLIGHT BEAM...
  • Page 119 Electrical Equipment RS 50 If an electric component does not work or works irregularly, or if the vehicle fails to start, it is necessary to check the fuse (1). For the checking: Turn the ignition switch to position “ ”, to avoid any accidental short circuit.

  • Page 120: Checking The Switches

    Electrical Equipment RS 50 CHECKING THE SWITCHES Carefully read the PERIODIC MAINTENANCE SCHEDULE. The vehicle is provided with two switches: Stoplight switch on the rear brake control lever (1). Stoplight switch on the front brake control lever (2). Make sure that there are no dirt or mud deposits on the switch;...
  • Page 121 Electrical Equipment RS 50 NOTES 6-30 chap. 6 Release 00 2000-11...
  • Page 122 Cycle Parts RS 50 Cycle Parts chap. 7 Release 00 2000-11...

  • Page 123: How To Apply Transfers

    Cycle Parts RS 50 HOW TO APPLY TRANSFERS If any parts of the bodywork are removed: WARNING If any parts of the bodywork are removed, take care not to score or damage plastic and painted parts when handling them. Proceed with caution.
  • Page 124 Cycle Parts RS 50 IMPORTANT If an application tape (1) is present, remove it 20-30 minutes after applying the transfer. The application tape is used to facilitate the applica- tion and positioning of marks and letters and to make the sticker thicker and easier to handle.

  • Page 125: Removing The Rider Saddle

    Cycle Parts RS 50 REMOVING THE RIDER SADDLE Carefully read the PERIODIC MAINTENANCE SCHEDULE. Position the vehicle on the stand. Insert the key (1) in the lock (2). Rotate the key (1) clockwise. Raise and remove the saddle (3). Remove the flap (4).

  • Page 126: Removing The Fairings

    Cycle Parts RS 50 REMOVING THE FAIRINGS Carefully read the PERIODIC MAINTENANCE SCHEDULE. WARNING Before carrying out the following operations, let the engine and the exhaust silencer cool down until they reach room temperature, in order to avoid burns. Position the vehicle on the stand.

  • Page 127: Removing The Fuel Tank

    Cycle Parts RS 50 REMOVING THE FUEL TANK Carefully read the paragraph FUEL and the PERI- ODIC MAINTENANCE SCHEDULE. WARNING Risk of fire. Wait until the engine and the exhaust silencer have completely cooled down. Fuel vapours are noxious for your health.

  • Page 128: Emptying The Fuel Tank

    Cycle Parts RS 50 Reinstall the tank in its working position. Loosen and remove nut (9) while locking screw (10). Remove screw (10) from the tank fixing seat on the frame. Collect washer (11). EMPTYING THE FUEL TANK Read through the paragraph FUEL.

  • Page 129: Removing The Air Filter Box

    Cycle Parts RS 50 REMOVING THE AIR FILTER BOX Read through the PERIODIC MAINTENANCE SCHEDULE. Remove the fuel tank (REMOVING THE FUEL TANK). Turn out screw (1) to loosen clamp (2) on the carbu- rettor intake sleeve. Unscrew and remove screw (3) fixing air filter box (4) to the frame.

  • Page 130: Removing The Handgrip From The Left Handlebar

    Cycle Parts RS 50 REMOVING THE HANDGRIP FROM THE LEFT HANDLEBAR Read through the section PRECAUTIONS AND GENERAL INFORMATION. Place the vehicle on the stand. Turn the ignition switch to “ ”. Lock counterpoise (1) and then loosen and remove screw (2).

  • Page 131: Removing The Clutch Lever

    Cycle Parts RS 50 REMOVING THE CLUTCH LEVER Read through the section PRECAUTIONS AND GENERAL INFORMATION. Place the vehicle on the stand. Turn the ignition switch to “ ” . Remove protective hood (1). Loosen nut (2) by turning it in until it comes into contact with adjuster (3).

  • Page 132: Removing The Throttle Control

    Cycle Parts RS 50 REMOVING THE THROTTLE CONTROL Read through the section PRECAUTIONS AND GENERAL INFORMATION. Place the vehicle on the stand. Turn the ignition switch to “ ” . Lock counterpoise (1) and then loosen and remove screw (2).

  • Page 133: Removing The Stoplight Switch

    Cycle Parts RS 50 REMOVING THE ELECTRICAL CON- TROLS FROM THE RIGHT-HAND HAN- DLEBAR Read through the section PRECAUTIONS AND GENERAL INFORMATION. Place the vehicle on the stand. Turn the ignition switch to “ ”. Simply disconnect throttle cable (1) from the block.

  • Page 134: Removing The Front Brake Control

    Cycle Parts RS 50 REMOVING THE FRONT BRAKE CON- TROL Read through the section PRECAUTIONS AND GENERAL INFORMATION. Place the vehicle on the stand. Turn the ignition switch to “ ”. Loosen and remove the two screws (1) securing front brake control (2).

  • Page 135: Removing The Right Handlebar

    Cycle Parts RS 50 REMOVING THE RIGHT HANDLEBAR Read through the section PRECAUTIONS AND GENERAL INFORMATION. Place the vehicle on the stand. Loosen and remove screw (1). Collect the related washer. Pull off right handlebar (2) with all the controls.

  • Page 136: Removing The Ignition Switch/Steering Lock

    Cycle Parts RS 50 REMOVING THE IGNITION SWITCH/ STEERING LOCK Read through the section PRECAUTIONS AND GENERAL INFORMATION. Place the vehicle on the stand. Turn the ignition switch to “ ”. Remove the left and right handlebars (REMOVING THE LEFT HANDLEBAR, REMOVING THE RIGHT HANDLEBAR).

  • Page 137: Removing The Front Fairing Glass

    Cycle Parts RS 50 IMPORTANT If necessary, repeat the same opera- tions to remove the other rearview mirror. WARNING After refitting the rearview mirrors, adjust them and then secure them by tightening the fastening nuts. REMOVING THE FRONT FAIRING GLASS Place the vehicle on the stand.

  • Page 138: Removing The Headlight

    Cycle Parts RS 50 Slightly shift front fairing (8) forward. Detach headlight connector (9). WARNING When refitting, ensure that connector (9) is prop- erly reattached. When handling plastic and painted parts, take care not to score or damage them. Remove the headlight (REMOVING THE HEAD- LIGHT).

  • Page 139: Removing The Instrument Panel Frame

    Cycle Parts RS 50 WARNING When refitting, be sure to properly reattach the electrical connections. Loosen and remove the three self-locking nuts (7) with the related washers. Tightening torque for nuts (7): 10 Nm (1 kgm) [7.4 Ft-lb]. Remove dashboard (6).

  • Page 140: Removing The Front Mudguard

    Cycle Parts RS 50 REMOVING THE FRONT MUDGUARD Read through the section PRECAUTIONS AND GENERAL INFORMATION. Place the vehicle on the stand. Loosen and remove the four screws (1). Tightening torque for screws (1): 7 Nm (0.7 kgm) [5.2 ft-lb] Collect the related self-locking nuts (2).

  • Page 141: Removing The Lower Fairing

    Cycle Parts RS 50 REMOVING THE LOWER FAIRING Read through the section PRECAUTIONS AND GENERAL INFORMATION. WARNING When handling plastic and painted parts, take care not to score or damage them. Place the vehicle on the rear stand WARNING Allow the engine and the exhaust terminal to cool down completely.

  • Page 142: Removing The Rear Fairing

    Cycle Parts RS 50 REMOVING THE REAR FAIRING Read through the section PRECAUTIONS AND GENERAL INFORMATION. WARNING Allow the engine and the exhaust terminal to cool down completely. Remove the rider saddle (REMOVING THE RIDER SADDLE). Loosen and remove nut (1) fixing the passenger saddle to the rear fairing.

  • Page 143: Removing The Rear Light

    Cycle Parts RS 50 REMOVING THE REAR LIGHT Read through the section PRECAUTIONS AND GENERAL INFORMATION. Turn the ignition switch to “ ”. Replace the rear light bulb (REPLACING THE REAR LIGHT BULB). Pull out and slightly loosen reflector (1).

  • Page 144: Removing The Saddle Support Cover

    Cycle Parts RS 50 REMOVING THE SADDLE SUPPORT COVER Read through the section PRECAUTIONS AND GENERAL INFORMATION. Remove the rider saddle (REMOVING THE RIDER SADDLE). Lift the fuel tank (LIFTING THE FUEL TANK). Loosen and remove the four screws (1).

  • Page 145: Removing The Rear Mudguard

    Cycle Parts RS 50 REMOVING THE REAR MUDGUARD Read through the section PRECAUTIONS AND GENERAL INFORMATION. Place the vehicle on the stand. WARNING Allow the engine and the exhaust terminal to cool down completely. Remove the two screws (1). Tightening torque for screws (1): 5 Nm (0.5 kgm) [3.7 ft-lb]...

  • Page 146: Removing The Rider Footrest Support (Left Side)

    Cycle Parts RS 50 Loosen and remove screws (4) under the saddle support cover. Tightening torque for screws (4): 24 Nm (2.4 kgm) [17.7 ft-lb] Remove footrest support (5) complete with the foot- rest. If necessary remove the footrest (REMOVING THE PASSENGER FOOTREST).

  • Page 147: Removing The Rider Footrest Support (Right Side)

    Cycle Parts RS 50 Remove gear lever (1) (REMOVING THE GEAR LEVER). Loosen and remove screws (2). Tightening torque for screws (2): 25 Nm (2.5 kgm) [18.4 ft-lb] Remove rider footrest support (3) complete with footrest (4). If necessary remove the footrest (REMOVING THE RIDER FOOTREST).

  • Page 148: Removing The Rider Footrest

    Cycle Parts RS 50 REMOVING THE RIDER FOOTREST Read through the section PRECAUTIONS AND GENERAL INFORMATION. Place the vehicle on the stand. CAUTION Allow the engine and the exhaust terminal to cool down completely. Remove circlip (1). Remove pin (2).

  • Page 149: Removing The Rear Brake Lever

    Cycle Parts RS 50 REMOVING THE REAR BRAKE LEVER Read through the section PRECAUTIONS AND GENERAL INFORMATION. Place the vehicle on the stand. Loosen and remove nut (1). Tightening torque for nut (1): 5 Nm (0.5 kgm) [3.7 ft-lb] Unhook spring (2).
  • Page 150 Cycle Parts RS 50 Loosen and remove screw (9). Tightening torque for screw (9): 12 Nm (1.2 kgm) [8.8 ft-lb] Collect washer (10). Loosen and remove screw (11) while supporting the exhaust silencer. Tightening torque for screw (11): 12 Nm (1.2 kgm) [8.8 ft-lb] Collect washer (12).

  • Page 151: Removing The Exhaust Terminal

    Cycle Parts RS 50 REMOVING THE EXHAUST TERMINAL Carefully read the section PRECAUTIONS AND GENERAL INFORMATION and the PERIODIC MAINTENANCE SCHEDULE. The cleaning of the exhaust silencer final pipe and of the exhaust terminal tailpipe must be carried out every 4000 km (2500 mi).

  • Page 152: Cleaning The Exhaust Silencer And The Exhaust Terminal

    Cycle Parts RS 50 CLEANING THE EXHAUST SILENCER AND THE EXHAUST TERMINAL Carefully read the section PRECAUTIONS AND GENERAL INFORMATION and the PERIODIC MAINTENANCE SCHEDULE. Remove the exhaust terminal (REMOVING THE EXHAUST TERMINAL). NOTE Prepare a flexible cleaning brush (1) with suitable diameter.

  • Page 153: Removing The Side Stand

    Cycle Parts RS 50 REMOVING THE SIDE STAND Read through the section PRECAUTIONS AND GENERAL INFORMATION. Place the vehicle on the rear stand Rear stand: 8705021. CAUTION Take care not to injure your hands while perform- ing the following operation.

  • Page 154: Removing The Chain Guide Shoe

    Cycle Parts RS 50 REMOVING THE CHAIN GUIDE SHOE Read through the section PRECAUTIONS AND GENERAL INFORMATION. Remove the swing arm (REMOVING THE SWING ARM). Loosen and remove screw (1). Tightening torque for screw (1): 3 Nm (0.3 kgm) [2.2 ft-lb] Collect cup (2).
  • Page 155 Cycle Parts RS 50 Loosen and remove screw (8). Tightening torque for screw (8): 3 Nm (0.3 kgm) [2.2 ft-lb] To avoid spilling the brake fluid, fasten brake fluid reservoir (9) to the frame in a vertical position using adhesive tape.
  • Page 156 Cycle Parts RS 50 IMPORTANT The following operation must also be performed on the other side of the vehicle. Loosen and remove the two screws (14) and (15). Tightening torque for screw (14): 24 Nm (2.4 kgm) [17.7 ft-lb] Tightening torque for screw (15): 47 Nm (4.7 kgm) [34.7 ft-lb]...

  • Page 157: Front Wheel

    Cycle Parts RS 50 FRONT WHEEL Wheel spindle. Speedometer gear cover Speedometer gear Washer Bearing Inner spacer Outer spacer Washer 7-36 chap. 7 Release 00 2000-11...

  • Page 158: Removing The Front Wheel Assembly

    Cycle Parts RS 50 REMOVING THE FRONT WHEEL ASSEM- Carefully read the PERIODIC MAINTENANCE SCHEDULE. While disassembling and reassembling the wheel, be careful not to damage the brake pipes, the discs and the pads. NOTE To remove the front wheel it is necessary to use the appropriate rear support stand.

  • Page 159: Disassembling The Front Wheel

    Cycle Parts RS 50 Lock the wheel pin (5) by means of a spanner. Unscrew and remove the nut (6), taking the washer (7). Wheel nut driving torque (6): 80 Nm (8 kgm) [59 Ft-lb]. Loosen the screw (8) of the wheel pin clamp.
  • Page 160 Cycle Parts RS 50 WARNING When reassembling, fit the bearings using a drift of the same diameter as the outer race of the bearings. Do not strike on the balls and/or the inner race. Be sure to drive the following parts fully home: - Right-hand bearing (1) on the hub.
  • Page 161 Cycle Parts RS 50 Using a comparator, check that radial runout (A) and axial runout (B) of rim (5) do not exceed the prescribed limit. Excessive runout is generally due to bearing wear or damage. If, after the bearings have been replaced, the runout still exceeds the limit, replace rim (5).
  • Page 162 Cycle Parts RS 50 CAUTION While reassembling the wheel, be careful not to damage the brake pipe, the disc and the pads. Insert the brake caliper (10) on the disc and position it so that its fastening holes and the holes on the sup- port are aligned.

  • Page 163: Front Brake

    Cycle Parts RS 50 FRONT BRAKE Brake lever Front brake pump Brake fluid reservoir Stoplight switch Brake fluid line from pump to caliper Brake caliper Air bleeder screw Brake pads Brake disc 7-42 chap. 7 Release 00 2000-11...

  • Page 164: Replacing The Front Brake Pads

    Cycle Parts RS 50 REPLACING THE FRONT BRAKE PADS Read through the section PRECAUTIONS AND GENERAL INFORMATION and the paragraph CHECKING THE WEAR OF THE BRAKE PADS. Place the vehicle on the stand. Using a hexagonal spanner, loosen and remove screws (1) fixing the pads to the front brake caliper.

  • Page 165: Removing The Front Brake Pump

    Cycle Parts RS 50 REMOVING THE FRONT BRAKE PUMP Refer to the paragraph REMOVING THE FRONT BRAKE CONTROL. REMOVING THE BRAKE DISC Read through the section PRECAUTIONS AND GENERAL INFORMATION. Remove the front wheel (REMOVING THE FRONT WHEEL ASSEMBLY). IMPORTANT To remove screws (1), it is advisable to...

  • Page 166: Front Fork

    Cycle Parts RS 50 FRONT FORK Seeger ring Sliding bushing Rod plug Sheath O-ring Sealing washer Spring Oil drain screw Plunger assembly Stop pad Dust ring Retaining ring Seal ring 7-45 chap. 7 Release 00 2000-11...

  • Page 167: Removing The Front Fork

    Cycle Parts RS 50 REMOVING THE FRONT FORK Read through the section PRECAUTIONS AND GENERAL INFORMATION. Remove the fairings (REMOVING THE SIDE FAIRINGS). Remove the lower fairing tip (REMOVING THE LOWER FAIRING). Remove the front wheel (REMOVING THE FRONT WHEEL ASSEMBLY).

  • Page 168: Disassembling The Fork

    Cycle Parts RS 50 DISASSEMBLING THE FORK Read through the section PRECAUTIONS AND GENERAL INFORMATION and the paragraph FORK OIL. IMPORTANT The left and right forks both have the same outside components. The operations described below refer to a single fork but apply to both.
  • Page 169 Cycle Parts RS 50 IMPORTANT Before completely removing spring (5), keep it just outside rod (6) for a few seconds so that part of the oil can drip into the rod. Remove spring (5). Tip the fork and pour the oil into container (7). Wait for the fork to be completely empty.
  • Page 170 Cycle Parts RS 50 WARNING The following operation must be carried out with firmness. Remove rod (6) complete with plunger (12) and stop (13). WARNING Plunger (12) must not be removed. Remove dust ring (11) (refer to previous figure) from rod (6).

  • Page 171: Checking Components

    Cycle Parts RS 50 CHECKING COMPONENTS Ensure that the sliding surface shows no signs of scoring and/or scratches. Very slight scoring can be removed by rubbing the surface with wet sandpaper (grain 1). WARNING A bent rod must NEVER be straightened because its structure would be weakened, making the vehicle unsafe.

  • Page 172: Reassembling The Fork

    Cycle Parts RS 50 WARNING Remove any dirt from the bushings taking care not to scratch their surface. Replace the following components with new ones: - oil seal (4) - dust ring (5) - the two O-rings on rod plug (6)
  • Page 173 Cycle Parts RS 50 WARNING For the following operation use a plastic mallet (4). Using a drift (5) of suitable diameter, fit a new oil seal in sheath (1) by striking a few blows with plastic mallet (4). Insert retaining ring (6) into the sheath until it clicks into the groove.
  • Page 174 Cycle Parts RS 50 With the rod in extended position, jam dust ring (10) onto sheath (1) (refer to previous figure). Hold fork (11) in a vertical position. Pour in fork oil (see TABLE OF LUBRICANTS) until it reaches the correct measurable level.

  • Page 175: Steering

    Cycle Parts RS 50 STEERING Head tube plug Washer Upper plate Ball bearing Ring Seal ring Washer Roller bearing Washer Lower plate with head tube 7-54 chap. 7 Release 00 2000-11...

  • Page 176: Removing The Steering

    Cycle Parts RS 50 REMOVING THE STEERING Read through the section PRECAUTIONS AND GEN- ERAL INFORMATION. Place the vehicle on the rear stand on an elevating platform (PLACING THE VEHICLE ON THE REAR STAND Remove the fairings (REMOVING THE SIDE FAIRINGS).

  • Page 177: Checking Components

    Cycle Parts RS 50 Loosen and remove adjusting ring (1). Remove roller bearing (3) and seal ring (4) from underneath the lower plate with head tube (2). Collect seal ring (dust ring) (5) and washer (6). Using a suitable extractor, remove bearing (7) from its seat in the frame.

  • Page 178: Refitting The Steering

    Cycle Parts RS 50 REFITTING THE STEERING IMPORTANT During reassembly, the vehicle and its front end must be positioned as during disassem- bly. Then proceed by following the removing proce- dure in reverse order. Apply a film of grease throughout the length of pin (1) and over roller bearing (2) (refer to the TABLE OF LUBRICANTS).

  • Page 179: Rear Wheel

    Cycle Parts RS 50 REAR WHEEL Rear sprocket Washer Chain guide shoe Chain guide shoe Washer Spacer Wheel spindle Caliper fixing plate Spacer Brake disc Bearings Spacer Wheel assembly Shim 7-58 chap. 7 Release 00 2000-11...

  • Page 180: Removing The Rear Wheel Assembly

    Cycle Parts RS 50 REMOVING THE REAR WHEEL ASSEMBLY Carefully read the PERIODIC MAINTENANCE SCHEDULE. Before carrying out the following operations, let the engine and the exhaust silencer cool down until they reach room temperature, in order to avoid burns.
  • Page 181 Cycle Parts RS 50 DISASSEMBLING THE REAR WHEEL Read through the section PRECAUTIONS AND GENERAL INFORMATION. Remove the wheel (REMOVING THE REAR WHEEL ASSEMBLY). Perform the operations described in the paragraph DISASSEMBLING THE FRONT WHEEL. Also remove the rear sprocket (REAR SPROCKET).

  • Page 182: Reinstalling The Rear Wheel

    Cycle Parts RS 50 REINSTALLING THE REAR WHEEL Read through the PERIODIC MAINTENANCE SCHEDULE. Moderately grease the wheel hub outer seats. WARNING The spacers differ in diameter. Take care not to invert them and to position them properly (see figure).
  • Page 183 Cycle Parts RS 50 Tighten nut (1). Tightening torque for nut (1): 80 Nm (8 kgm) [59 ft-lb] CAUTION After reinstalling the wheel, repeatedly actuate the rear brake lever and check the operation of the braking system. Check the alignment of the wheel.

  • Page 184: Rear Brake

    Cycle Parts RS 50 REAR BRAKE Brake fluid reservoir Brake fluid line from reservoir to pump Stoplight switch Brake pump Brake fluid line from pump to caliper Rear brake lever Brake disc Bleeder valve Brake caliper Brake pads 7-63 chap. 7...

  • Page 185: Replacing The Rear Brake Pads

    Cycle Parts RS 50 REPLACING THE REAR BRAKE PADS Read through the section PRECAUTIONS AND GENERAL INFORMATION and the paragraph CHECKING THE WEAR OF THE BRAKE PADS. Place the vehicle on the stand. Remove brake caliper cover (1). WARNING Before removing pin (3), check the position of safety spring (4).

  • Page 186: Removing The Rear Brake Disc

    Cycle Parts RS 50 REMOVING THE REAR BRAKE DISC Read through the section PRECAUTIONS AND GENERAL INFORMATION. Remove the rear wheel (REMOVING THE REAR WHEEL ASSEMBLY). IMPORTANT To remove screws (1), it is advisable to use an air driver gun, which is capable of giving the screws a sharp blow, allowing them to be released ®...

  • Page 187: Removing The Rear Suspension

    Cycle Parts RS 50 Loosen and shift hose clamp (4). Remove pipe (5) and the two screws (6). Tightening torque for screws (6): 10 Nm (1.0 kgm) [7.4 ft-lb] Remove pump (7) by pulling it forward. IMPORTANT When refitting the pump, restore the...

  • Page 188: Checking The Suspension Components

    Cycle Parts RS 50 Remove the four T bushes (5) and the two Silentblocs (6). IMPORTANT Wash all the components with a clean detergent. Check the components (CHECKING THE SUSPEN- SION COMPONENTS). CHECKING THE SUSPENSION COMPO- NENTS WARNING Ensure that no components are visibly distorted, broken, cracked and/or dented.

  • Page 189: Removing The Drive Chain

    Cycle Parts RS 50 REMOVING THE DRIVE CHAIN Carefully read the PERIODIC MAINTENANCE SCHEDULE and the section PRECAUTIONS AND GENERAL INFORMATION. Place the vehicle on the rear stand (PLACING THE VEHICLE ON THE REAR STAND OPT). Rear stand: 8705021. CAUTION Before removing the drive chain, ensure that the gears are in neutral.

  • Page 190: Removing The Swing Arm

    Cycle Parts RS 50 REMOVING THE SWING ARM Read through the section PRECAUTIONS AND GENERAL INFORMATION. Remove the side fairings (REMOVING THE SIDE FAIRINGS). Remove the lower fairing tip (REMOVING THE LOWER FAIRING). Remove the exhaust silencer (REMOVING THE EXHAUST SILENCER AND THE EXHAUST TERMI- NAL).
  • Page 191 Cycle Parts RS 50 IMPORTANT Have the specially designed tool ready (swing arm pivot adjusting bush spanner). Using bush spanner (6) loosen and remove lock ring (7). Swing arm pivot adjusting bush spanner: 8101945 WARNING Owing to the weight of the rear end, the following operations require the presence of a second operator.

  • Page 192: Disassembling The Swing Arm

    Cycle Parts RS 50 DISASSEMBLING THE SWING ARM Read through the section PRECAUTIONS AND GENERAL INFORMATION. Remove bushes (1). Remove O-rings (2). WARNING When reassembling, fit two new O-rings (2). Remove inner spacer (3). Using a drift of suitable diameter, remove inner bushes (4).

  • Page 193: Reassembling The Swing Arm

    Cycle Parts RS 50 REASSEMBLING THE SWING ARM Read though the section PRECAUTIONS AND GENERAL INFORMATION. Apply a film of lubricating grease throughout the length of swing arm pivot (1) (TABLE OF LUBRI- CANTS). Using a drift of suitable diameter, drive home inner bushes (2).
  • Page 194 Cycle Parts RS 50 IMPORTANT Have the specially designed tool (9) ready (swing arm pivot adjusting bush spanner). Swing arm pivot adjusting bush spanner: 8101945. Fit and manually tighten adjusting ring (10) using tool (9). IMPORTANT The flat side of adjusting ring (10) must be in contact with the frame.
  • Page 195 Cycle Parts RS 50 NOTES 7-74 chap. 7 Release 00 2000-11...
  • Page 196 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...

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