APRILIA RS 50 - 2001 Spécifications

Workshop manualRS 50aprilia s.p.a.Via G. Galilei, 130033 Noale (VE)Tel. +39 (0) 41 - 5829111Fax +39 (0) 41 - 441054www.aprilia.comwww.serviceaprilia.c

RS 509Release 00 2001-03WARNINGAutomatic Switch-on Device versionoptionalREFITTING COMPONENTSNever use a circlip twice. When a circlip is removed, it

Electrical systemRS 50ch. 66-76Release 00 2001-03RECHARGE AND GENERAL POWERSUPPLY CIRCUITLocation of components see (LOCATION OF COM-PONENTS).WIRING D

Electrical systemRS 50ch. 66-8Release 00 2001-03TROUBLESHOOTINGA. BATTERY DOESN’T STAY CHARGEDCheck the fuse, replacing it if necessary.Replace the re

Electrical systemRS 50ch. 66-96Release 00 2001-03CHECK DATACHECKING THE GENERATORDisconnect the yellow wire from the regulator.Start the engine and ru

Electrical systemRS 50ch. 66-10Release 00 2001-03TECHNICAL DATAStarter motor ... 12 V - 150 WBrush wear limit.

Electrical systemRS 50ch. 66-116Release 00 2001-03CHECK DATACHECKING THE STARTER RELAYDisconnect all the wires from the relay.Using a multimeter with

Electrical systemRS 50ch. 66-12Release 00 2001-03SENSOR CIRCUITLocation of components see (LOCATION OF COM-PONENTS).WIRING DIAGRAM8) Oil reserve senso

Electrical systemRS 50ch. 66-136Release 00 2001-03B. STAYS LIT WHEN OIL LEVEL IS SUFFICIENTCheck the wiring connections.Check the oil level sensor (CH

Electrical systemRS 50ch. 66-14Release 00 2001-03TECHNICAL DATADirection indicatorbulbs...12 V - 10 W B.A. 15 S

Electrical systemRS 50ch. 66-156Release 00 2001-03HORN CIRCUITLocation of components see (LOCATION OF COM-PONENTS).WIRING DIAGRAM17) Horn button31) Ho

Electrical systemRS 50ch. 66-16Release 00 2001-03B. SOUNDS CONTINUOUSLYCheck the wiring connections.Check the horn button (CHECKING THE HORNBUTTON).CH

RS 5010Release 00 2001-03NOTES

Electrical systemRS 50ch. 66-176Release 00 2001-03BRAKING LIGHTS CIRCUITLocation of components see (LOCATION OF COM-PONENTS).WIRING DIAGRAM7) Brake li

Electrical systemRS 50ch. 66-18Release 00 2001-03B. BRAKE LIGHT DOESN’T SWITCH ONCheck the bulb and bulb holder.Check the wiring connections.Check the

Electrical systemRS 50ch. 66-196Release 00 2001-03LIGHT CIRCUITLocation of components see (LOCATION OF COM-PONENTS).WIRING DIAGRAM3) Regulator11) Low

Electrical systemRS 50ch. 66-20Release 00 2001-03LIGHT CIRCUIT Location of components see (LOCATION OF COM-PONENTS).WIRING DIAGRAM3) Regulator11) Low

Electrical systemRS 50ch. 66-216Release 00 2001-03TROUBLESHOOTINGA. A LIGHT DOESN’T WORKCheck the bulb.Check for voltage on the bulb holder terminals.

Electrical systemRS 50ch. 66-22Release 00 2001-03WATER TEMPERATURE SENSORTROUBLESHOOTINGA. TEMPERATURE READING TOO LOWCheck the connections.Check that

Electrical systemRS 50ch. 66-236Release 00 2001-03As illustrated in the figure, connect a multimeter (D)with the scale set to ohms to the thermistor (

Electrical systemRS 50ch. 66-24Release 00 2001-03BULBSRead carefully (MAINTENANCE).Risk of fire. Keep fuel and other flammable sub-stances away from t

Electrical systemRS 50ch. 66-256Release 00 2001-03CHANGINGHIGH BEAM BULBNOTE Remove the bulb sockets one by one in sucha way as to avoid replacing the

Electrical systemRS 50ch. 66-26Release 00 2001-03CHANGINGTHE FRONT AND REARTURN SIGNAL BULBSRead carefully (BULBS).NOTE Before changing a bulb, check

General informationGeneral informationRS 50ch. 1Release 00 2001-031-11

Electrical systemRS 50ch. 66-276Release 00 2001-03NOTE Ensure that the orientation of your replace-ment bulb is identical to that of the original bulb

Electrical systemRS 50ch. 66-28Release 00 2001-03To adjust the beam:Remove the front part of the fairing, see (REMOVINGTHE FRONT PART OF THE FAIRING).

Electrical systemRS 50ch. 66-296Release 00 2001-03CHANGE FUSESRead carefully (SERVICING SCHEDULE).Do not repair faulty fuses.Use only recommended fuse

Electrical systemRS 50ch. 66-30Release 00 2001-03If an electric component does not work or worksirregularly, or if the motorcycle fails to start, it i

Electrical systemRS 50ch. 66-316Release 00 2001-03CHECKING THE SWITCHESRead carefully (SERVICING SCHEDULE).The motorcycle is equipped with three switc

Electrical systemRS 50ch. 66-32Release 00 2001-03NOTES

Body workBody workRS 50ch. 77-17Release 00 2001-03

Body workRS 50ch. 77-2Release 00 2001-03NOTE Do not lift up the corners and/or sides of thetransfer.Dry the transfer by wiping it from the center outw

Body workRS 50ch. 77-37Release 00 2001-03NOTE The application tape (1), if present, must beremoved 20-30 minutes after the application of thetransfer.

Body workRS 50ch. 77-4Release 00 2001-03REMOVING THE RIDER SADDLERead carefully (SERVICING SCHEDULE).Position the motorcycle on the stand.Insert the k

General informationRS 50Release 00 2001-03ch. 11-2POSITION OF SERIAL NUMBERSThese numbers are required for vehicle registration.NOTE The alteration of

Body workRS 50ch. 77-57Release 00 2001-03REMOVING THE SIDE FAIRINGSRead carefully (SERVICING SCHEDULE).Before carrying out the following operations, l

Body workRS 50ch. 77-6Release 00 2001-03Handle with care.While removing the fuel tank (5), DO NOT force thefuel line (6).Grasp the front part of the f

Body workRS 50ch. 77-77Release 00 2001-03Replace the tank in its working position.Loosen and remove the nut (9) that holds the bolt(10).After removing

Body workRS 50ch. 77-8Release 00 2001-03CAUTIONProceed with great care when removing the airbox.Lift up the rear end of the air box to withdraw it fro

Body workRS 50ch. 77-97Release 00 2001-03REMOVINGTHE LEFT HANDLEBAR HANDGRIPRead carefully (PRECAUTIONS AND GENERALINFORMATION).Position the motorcycl

Body workRS 50ch. 77-10Release 00 2001-03REMOVING THE CLUTCH CONTROLRead carefully (PRECAUTIONS AND GENERALINFORMATION).Position the motorcycle on the

Body workRS 50ch. 77-117Release 00 2001-03REMOVING THE THROTTLE CONTROLRead carefully (PRECAUTIONS AND GENERALINFORMATION).Position the motorcycle on

Body workRS 50ch. 77-12Release 00 2001-03REMOVING THE RIGHT HANDLEBARELECTRICAL CONTROLSRead carefully (PRECAUTIONS AND GENERALINFORMATION).Position t

Body workRS 50ch. 77-137Release 00 2001-03REMOVING THE FRONT BRAKECONTROLRead carefully (PRECAUTIONS AND GENERALINFORMATION).Position the motorcycle o

Body workRS 50ch. 77-14Release 00 2001-03REMOVING THE RIGHT HANDLEBARRead carefully (PRECAUTIONS AND GENERALINFORMATION).Position the motorcycle on th

General informationRS 50ch. 1Release 00 2001-031-31ENGINE NUMBERThe engine number is stamped on the rear of theengine, next to the sprocket.SAFETY WAR

Body workRS 50ch. 77-157Release 00 2001-03REMOVING THE IGNITION SWITCH/STEERING LOCKRead carefully (PRECAUTIONS AND GENERALINFORMATION).Position the m

Body workRS 50ch. 77-16Release 00 2001-03NOTE Repeat the same steps to remove the otherrear view mirror.NOTE After refitting, set the rear view mirror

Body workRS 50ch. 77-177Release 00 2001-03Move the front fairing (8) slightly forward.Disconnect the headlight electrical connector (9).NOTE When refi

Body workRS 50ch. 77-18Release 00 2001-03NOTE Make sure the electrical connections arecorrect when refitting.Loosen and remove the 3 self-locking nuts

Body workRS 50ch. 77-197Release 00 2001-03REMOVING THE FRONT MUDGUARDRead carefully (PRECAUTIONS AND GENERALINFORMATION).Position the motorcycle on th

Body workRS 50ch. 77-20Release 00 2001-03REMOVING THE LOWER FAIRINGRead carefully (PRECAUTIONS AND GENERALINFORMATION).Handle plastic and painted part

Body workRS 50ch. 77-217Release 00 2001-03REMOVING THE REAR FAIRINGRead carefully (PRECAUTIONS AND GENERALINFORMATION).Wait until the engine and exhau

Body workRS 50ch. 77-22Release 00 2001-03REMOVING THE REAR LIGHTRead carefully (PRECAUTIONS AND GENERALINFORMATION).Switch the ignition key to the ““

Body workRS 50ch. 77-237Release 00 2001-03REMOVING THE PILLAR COVERRead carefully (PRECAUTIONS AND GENERALINFORMATION).Remove the rider saddle (REMOVI

Body workRS 50ch. 77-24Release 00 2001-03REMOVING THE REAR MUDGUARDRead carefully (PRECAUTIONS AND GENERALINFORMATION).Position the motorcycle on the

General informationRS 50Release 00 2001-03ch. 11-4Never try to siphon gasoline by sucking it withyour mouth.Use a manual pump or a similar system.If y

Body workRS 50ch. 77-257Release 00 2001-03Loosen and remove the screws (4) under the pillarcover.Torque setting for screws (4):24 Nm (2.4 kgm) [17.7 F

Body workRS 50ch. 77-26Release 00 2001-03Remove the shift lever (1) (REMOVING THE SHIFTLEVER).Loosen and remove the screws (2).Torque setting for scre

Body workRS 50ch. 77-277Release 00 2001-03REMOVING THE FRONT FOOTRESTRead carefully (PRECAUTIONS AND GENERALINFORMATION).Position the motorcycle on th

Body workRS 50ch. 77-28Release 00 2001-03REMOVING THE BRAKE PEDALRead carefully (PRECAUTIONS AND GENERALINFORMATION).Position the motorcycle on the st

Body workRS 50ch. 77-297Release 00 2001-03Loosen and remove the screw (9).Torque setting for screw (9):12 Nm (1.2 kgm) [8.8 Ft-lb].Take off the washer

Body workRS 50ch. 77-30Release 00 2001-03Unscrew and remove the screw (1) and take off thewasher.Take off the support (2).Support the muffler (3) to s

Body workRS 50ch. 77-317Release 00 2001-03CLEANING THE EXHAUST PIPEAND MUFFLERRead carefully (PRECAUTIONS AND GENERALINFORMATION) and (SERVICING SCHED

Body workRS 50ch. 77-32Release 00 2001-03REMOVING THE SIDE STANDRead carefully (PRECAUTIONS AND GENERALINFORMATION).Position the motorcycle on the rea

Body workRS 50ch. 77-337Release 00 2001-03REMOVING THE CHAIN GUIDERead carefully (PRECAUTIONS AND GENERALINFORMATION).Remove the swing arm (REMOVING T

Body workRS 50ch. 77-34Release 00 2001-03Loosen and remove the screw (8).Torque setting for screw (8):3 Nm (0.3 kgm) [2.2 Ft-lb].Tape or wire the brak

General informationRS 50ch. 1Release 00 2001-031-51LUBRICANTSProper vehicle lubrication is critical to safe opera-tion. Failure to maintain proper lub

Body workRS 50ch. 77-357Release 00 2001-03NOTE The following operation must be performedfrom the opposite side of the motorcycle.Loosen and remove the

Body workRS 50ch. 77-36Release 00 2001-03FRONT WHEELKey1) Axle2) Odometer drive cover3) Odometer drive4) Washer5) Bearing6) Internal spacer7) External

Body workRS 50ch. 77-377Release 00 2001-03REMOVINGTHE COMPLETE FRONT WHEELRead carefully (SERVICING SCHEDULE).While disassembling and reassembling the

Body workRS 50ch. 77-38Release 00 2001-03Prevent the axle (5) from rotating with an appropriateAllen wrench.Remove the nut (6) and washer (7).Wheel nu

Body workRS 50ch. 77-397Release 00 2001-03When refitting the bearings, use a drift with thesame diameter as the outside race of the bearings.Do not dr

Body workRS 50ch. 77-40Release 00 2001-03RIMUsing a dial gauge, check that the radial runout (A)and axial runout (B) on the rim (5) do not exceed thes

Body workRS 50ch. 77-417Release 00 2001-03While reassembling the wheel, be careful not todamage the brake line, the disc and the pads.Install the brak

Body workRS 50ch. 77-42Release 00 2001-03FRONT BRAKEKey1) Brake lever2) Front brake master cylinder3) Brake fluid reservoir4) Brake light switch5) Mas

Body workRS 50ch. 77-437Release 00 2001-03Always replace both pads and make sure they arecorrectly positioned in the caliper.Reinsert the screws (1) t

Body workRS 50ch. 77-44Release 00 2001-03REMOVING THE FRONT BRAKE MASTERCYLINDERSee (REMOVING THE FRONT BRAKE CONTROL).REMOVING THE BRAKE DISCRead car

General informationRS 50Release 00 2001-03ch. 11-6FORK OILBy changing the damper settings and/or theviscosity of the oil contained in them, the suspen

Body workRS 50ch. 77-457Release 00 2001-03FRONT FORKKey1) Circlip2) Tube plug3) O-ring4) Spring5) Complete plunger6) End bumper7) Fork tube8) Dust cov

Body workRS 50ch. 77-46Release 00 2001-03REMOVING THE FRONT FORKRead carefully (PRECAUTIONS AND GENERALINFORMATION).Remove the fairings (REMOVING THE

Body workRS 50ch. 77-477Release 00 2001-03DISASSEMBLING THE FORKRead carefully (PRECAUTIONS AND GENERALINFORMATION) and (FORK OIL).NOTE The right and

Body workRS 50ch. 77-48Release 00 2001-03NOTE Before completely removing the spring (5),hold it just out of the tube (6) for a few seconds so thatpart

Body workRS 50ch. 77-497Release 00 2001-03NOTE The following operation requires the applica-tion of considerable force.Withdraw the fork tube (6) comp

Body workRS 50ch. 77-50Release 00 2001-03CHECKING THE COMPONENTSTUBECheck for scoring and/or scratches on the slidesurface. Very slight scoring can be

Body workRS 50ch. 77-517Release 00 2001-03Remove any impurities from the bushes, beingcareful not to scratch the surfaces.Replace the following parts

Body workRS 50ch. 77-52Release 00 2001-03CAUTIONUse a plastic-headed mallet (4) for the followingoperations.Using a drift of suitable diameter (5), fi

Body workRS 50ch. 77-537Release 00 2001-03With the tube fully extended, fit the dust cover (10) onto the slider (1) (see pervious figure).Hold the for

Body workRS 50ch. 77-54Release 00 2001-03STEERINGKey1) Steering stem tube2) Washer3) Upper plate4) Ball bearing5) Ring nut6) Retainer ring7) Washer8)

General informationRS 50ch. 1Release 00 2001-031-71BE SURE TO KEEP THE DRAINED COOLANTAWAY FROM CHILDREN AND PETS.IT IS SWEET TASTING, AS WELL AS EXTR

Body workRS 50ch. 77-557Release 00 2001-03REMOVING THE STEERINGRead carefully (PRECAUTIONS AND GENERALINFORMATION) and (STEERING).Position the motorcy

Body workRS 50ch. 77-56Release 00 2001-03Loosen and remove the adjustor ring nut (1).Remove the roller bearing (3) and the retainer ring (4)from the

Body workRS 50ch. 77-577Release 00 2001-03REFITTING THE STEERINGNOTE For reassembly, the motorcycle and front forkmust be positioned as for disassemb

Body workRS 50ch. 77-58Release 00 2001-03REAR WHEELKey1) Nut2) Washer3) Chain guide4) Spacer5) Caliper mounting plate6) Spacer7) Brake disc8) Bearings

Body workRS 50ch. 77-597Release 00 2001-03REMOVINGTHE COMPLETE REAR WHEELRead carefully (SERVICING SCHEDULE).Before proceeding, allow the engine and e

Body workRS 50ch. 77-60Release 00 2001-03DISASSEMBLING THE REAR WHEELRead carefully (PRECAUTIONS AND GENERALINFORMATION).Remove the wheel (REMOVING TH

Body workRS 50ch. 77-617Release 00 2001-03REASSEMBLY REAR WHEELRead carefully (SERVICING SCHEDULE).Apply a thin film of grease to the outer seals of t

Body workRS 50ch. 77-62Release 00 2001-03Tighten the nut (1).Wheel nut (1) tightening torque:59 Ft-lb (8 kgm) [80 Nm].After servicing the brakes, alwa

Body workRS 50ch. 77-637Release 00 2001-03REAR BRAKEKey1) Brake fluid reservoir2) Reservoir-to-master cylinder brake fluid tube3) Brake light switch4)

Body workRS 50ch. 77-64Release 00 2001-03CHANGINGTHE REAR BRAKE PADSRead carefully (PRECAUTIONS AND GENERALINFORMATION) and (CHECKING THE WEAR ONTHE B

General informationRS 50Release 00 2001-03ch. 11-8On the basis of the desired freezing temperature of the coolant mixture, add to the water the percen

Body workRS 50ch. 77-657Release 00 2001-03CHECKING THE BRAKE DISCNOTE Checking the brake disc for warpage must bedone with the brake discs installed o

Body workRS 50ch. 77-66Release 00 2001-03Loosen and move the tube clamp (4).Withdraw the tube (5) and remove the 2 screws (6).Torque setting for screw

Body workRS 50ch. 77-677Release 00 2001-03Remove the 4 T-bushes (5) and withdraw the 2 silent-blocks (6).NOTE Wash all components with fire-proof solv

Body workRS 50ch. 77-68Release 00 2001-03REMOVING THE DRIVE CHAINRead carefully (SERVICE SCHEDULE) and (PRE-CAUTIONS AND GENERAL INFORMATION).Position

Body workRS 50ch. 77-697Release 00 2001-03REMOVING THE SWING ARMRead carefully (PRECAUTIONS AND GENERALINFORMATION).Remove the side fairings (REMOVING

Body workRS 50ch. 77-70Release 00 2001-03NOTE Use the special tool (swing arm pin adjust-ment socket wrench).Using the special socket wrench (6),

Body workRS 50ch. 77-717Release 00 2001-03Using a drift of suitable diameter, remove the internalbushes (4).NOTE Wash all components with clean deterg

Body workRS 50ch. 77-72Release 00 2001-03REASSEMBLING THE SWING ARMRead carefully (PRECAUTIONS AND GENERALINFORMATION).Install the internal spacer (3)

Body workRS 50ch. 77-737Release 00 2001-03Fully tighten the pin (1).Torque setting for pin (1):70 Nm (7 kgm) [5.2 Ft-lb].NOTE From this point, proceed

Body workRS 50ch. 77-74Release 00 2001-03NOTES

IntroductionThis manual contains information on how to performthe usual vehicle service procedures. This manualdoes not describe all of the procedures

General informationRS 50ch. 1Release 00 2001-031-91WARNINGDo not use fluids other than those specified and do not top up with different fluids, as thi

Workshop manualRS 50aprilia s.p.a.Via G. Galilei, 130033 Noale (VE)Tel. +39 (0) 41 - 5829111Fax +39 (0) 41 - 441054www.aprilia.comwww.serviceaprilia.c

General informationRS 50Release 00 2001-03ch. 11-10POSITION OF THE WARNING ADHESIVE LABELS12345786915141316101112

General informationRS 50ch. 1Release 00 2001-031-111Ref. Description12345678Exhaust pipe stamping.Muffler stamping.USE ONLY FLUID FOR SEALED CIR

General informationRS 50Release 00 2001-03ch. 11-12SPARE PARTSIf any parts have to be replaced, use only original aprilia spare parts.aprilia original

General informationRS 50ch. 1Release 00 2001-031-131CONTINUED NumberModelDELLORTO SHA 14/12CARBURETOR1FuelSuper-rated unleaded petrol (4-star ) or u

General informationRS 50Release 00 2001-03ch. 11-14LUBRICANT CHARTGearbox oil (recommended): F. C., SAE 75W - 90 or GEAR SYNTH, SAE 75W - 90.As an

General informationRS 50ch. 1Release 00 2001-031-151SPECIAL TOOLS Special service tools must be used for removing andfitting components correctly and

General informationRS 50ch. 11-16Release 00 2001-03POSITIONING THE MOTORCYCLE ON THE REARSUPPORT STANDLoosen the knob (1).Remove the front fork suppor

General informationRS 50ch. 1Release 00 2001-031-171GENERAL SPECIFICATIONS FORTORQUE WRENCH SETTINGSThe standard torque wrench settings for screws and

General informationRS 50Release 00 2001-03ch. 11-18ABBREVIATIONS / SYMBOLS / INITIALS# = number< = less than> = greater than≤≤≤≤≤ = equal to or

RS 502Release 00 2001-03CONTENTSChapter 1POSITION OF SERIAL NUMBERS ...

Routine maintenanceoperationsRoutine maintenance operationsRS 50ch. 2Release 00 2001-032-12

Routine maintenance operationsRS 50Release 00 2001-03ch. 22-2This section describes the routine maintenanceprocedures for the main components of the m

Routine maintenance operationsRS 50ch. 2Release 00 2001-032-32SERVICING SCHEDULEu Battery electrolyte level C Cu Spark plug P C Sc Carburetor Pc Wheel

Routine maintenance operationsRS 50Release 00 2001-03ch. 22-4LUBRICATION POINTSRegular, lubrication, using the correct lubricants, is animportant fact

Routine maintenance operationsRS 50ch. 2Release 00 2001-032-52ARRANGEMENT OF THE INSTRUMENTS /CONTROLSKEY1) Ignition switch/ steering lock ( - - )2

Routine maintenance operationsRS 50Release 00 2001-03ch. 22-6BATTERYRead carefully (GENERAL PRECAUTIONS ANDINFORMATION).Two types of batteries are sol

Routine maintenance operationsRS 50ch. 2Release 00 2001-032-72If your battery needs to be charged, use a con-stant voltage, or “taper” charger, with a

Routine maintenance operationsRS 50Release 00 2001-03ch. 22-8CHECKING THE ELECTROLYTE LEVELRead carefully (BATTERY).To check the electrolyte level, pr

Routine maintenance operationsRS 50ch. 2Release 00 2001-032-92LONG PERIOD OF BATTERY NON-USEIf your motorcycle remains unused for more than a couple o

Routine maintenance operationsRS 50ch. 22-10Release 00 2001-03If necessary, clean the spark plug with a proprietaryspark plug cleaner, and a stainless

RS 503Release 00 2001-03FASTENERS ...

Routine maintenance operationsRS 50ch. 22-112Release 00 2001-03AIR CLEANERDo not use gasoline or flammable solvents towash the air cleaner, in order t

Routine maintenance operationsRS 50Release 00 2001-03ch. 22-12ADJUSTING THE THROTTLE CONTROLRead carefully (SERVICING SCHEDULE).If the throttle sticks

Routine maintenance operationsRS 50ch. 2Release 00 2001-032-132CHECKING THE GEARBOX OILRead carefully (GEARBOX OIL) and (SERVICINGSCHEDULE).Check the

Routine maintenance operationsRS 50ch. 22-14Release 00 2001-03CAUTIONDanger of falling or turning over.As soon as the motorcycle is stood up, i.e. mov

Routine maintenance operationsRS 50ch. 22-152Release 00 2001-03CAUTIONThe engine, when hot, contains oil at a hightemperature: proceed with great care

Routine maintenance operationsRS 50ch. 22-16Release 00 2001-03Keep the motorcycle in a vertical position with the twowheels on the ground.Position a c

Routine maintenance operationsRS 50ch. 22-172Release 00 2001-03WARNINGTo fill the 2 stroke oil tank:Remove the rider saddle, see (REMOVING THERIDER SA

Routine maintenance operationsRS 50ch. 22-18Release 00 2001-03Remove the two screws (1) shown in the figure andtake off the oil pump cover.Get a conta

Routine maintenance operationsRS 50ch. 22-192Release 00 2001-03WARNINGWARNINGCoolant is poisonous! Do not ingest coolant underany circumstance.Should

Routine maintenance operationsRS 50ch. 22-20Release 00 2001-03CHECKING AND TOPPING UPNever remove the cap (1) when the engine is evenwarm, since the c

RS 504Release 00 2001-03REMOVING THE LEFT HANDLEBAR HANDGRIP ... 7-9REMOVI

Routine maintenance operationsRS 50ch. 22-212Release 00 2001-03CHANGING THE COOLANTRead carefully (PRECAUTIONS AND GENERALINFORMATION) and (COOLANT).C

Routine maintenance operationsRS 50Release 00 2001-03ch. 22-22CHECKING AND TOPPING UP THEBRAKE FLUIDNOTE This motorcycle is equipped withfront and rea

Routine maintenance operationsRS 50ch. 22-232Release 00 2001-03This motorcycle has front and rear hydraulic discbrakes.As the friction pads wear down,

Routine maintenance operationsRS 50ch. 22-24Release 00 2001-03Check the efficiency of the brakes.If the brake lever has too much play or is tooloose,

Routine maintenance operationsRS 50ch. 2Release 00 2001-032-252REAR BRAKECHECKING THE SYSTEMNOTE Carry out these checks only on a firm, flatsurface su

Routine maintenance operationsRS 50ch. 22-26Release 00 2001-03WARNINGFill to the “MAX” level only when new pads arefitted.The fluid level decreases gr

Routine maintenance operationsRS 50ch. 22-272Release 00 2001-03Keep checking the fluid as it flows out of the reservoir(2), and tighten up the bleed v

Routine maintenance operationsRS 50ch. 22-28Release 00 2001-03Keep checking the fluid as it flows out of the reservoir(2), and tighten up the bleed va

Routine maintenance operationsRS 50ch. 22-292Release 00 2001-03Tighten up the bleed valve (1), pump the brake lever afew times, then keep it fully eng

Routine maintenance operationsRS 50Release 00 2001-03ch. 22-30Be sure there is the specified clearance betweenthe master cylinder push rod and the mas

RS 505Release 00 2001-03REAR WHEEL ...

Routine maintenance operationsRS 50ch. 2Release 00 2001-032-312ADJUSTING THE CLUTCHThe clutch needs adjusting when the engine cuts out,or when the mot

Routine maintenance operationsRS 50ch. 22-32Release 00 2001-03CHECKING THE PLAY ON THE BEARINGSRead carefully (PRECAUTIONS AND GENERALINFORMATION).Uns

Routine maintenance operationsRS 50ch. 22-332Release 00 2001-03Reposition the top plate (5), fitting it in correctly.Position the washer (2) on the sl

Routine maintenance operationsRS 50ch. 22-34Release 00 2001-03Do not ever operate your motorcycle with a dam-aged chain. This could cause wheel seizur

Routine maintenance operationsRS 50ch. 22-352Release 00 2001-03ADJUSTMENTNOTE To adjust the chain it is necessary to use theappropriate rear support s

Routine maintenance operationsRS 50Release 00 2001-03ch. 22-36CLEANING AND LUBRICATIONCarry out the adjustment, lubrication, cleaningand change of the

Routine maintenance operationsRS 50ch. 2Release 00 2001-032-372WARNINGDo not use the motorcycle if the tire wear indicatorssignal that a change is nec

Routine maintenance operationsRS 50ch. 22-38Release 00 2001-03New tires are often covered with a slippery moldrelease compound. Scrub the tires in by

Routine maintenance operationsRS 50ch. 2Release 00 2001-032-3922 STROKE OIL PIPES/HOSESCheck the state of the 2 stroke oil pipes/hoses (2)every 4,000

Routine maintenance operationsRS 50Release 00 2001-03ch. 22-40FRAMEDescription Qty. Screw/nutNm (Ft-lb)Kgm CodePillar to frame 2 hex fl. M8x25 24 (17.

RS 506Release 00 2001-03SAFETY WARNINGSThroughout this manual, you will see the following symbols:When you find this symbol on the vehicle or in the m

Routine maintenance operationsRS 50ch. 2Release 00 2001-032-412ENGINEDescription Qty. Screw/nutNm (Ft-lb)Kgm CodeShift lever pin 1 Dwg.5058 12 (8.8) 1

Routine maintenance operationsRS 50Release 00 2001-03ch. 22-42DASHBOARDDescription Qty. Screw/nutNm (Ft-lb)Kgm CodeDashboard to arch 3 Nut M6 10 (7.4)

Routine maintenance operationsRS 50ch. 2Release 00 2001-032-432BODYDescription Qty. Screw/nutNm (Ft-lb)Kgm CodeReflector to front mudguard 4 Nut M4 3

Routine maintenance operationsRS 50Release 00 2001-03ch. 22-44NOTES

EngineEngineRS 50ch. 33-13Release 00 2001-03

EngineRS 50ch. 33-2Release 00 2001-03ENGINE COMPONENTS THAT CAN BEREMOVED WITHOUT REMOVING THEENGINE FROM THE FRAMERead carefully (PRECAUTIONS AND GEN

EngineRS 50ch. 33-33Release 00 2001-03Switch the ignition key to the “ “ position.Position the motorcycle on the rear stand (POSI-TIONING THE MOTORC

EngineRS 50ch. 33-4Release 00 2001-03Unscrew the ring nut (1) and remove the tachometercable (2).Slide the boot (3) back.Loosen the nut (4) by screwin

EngineRS 50ch. 33-53Release 00 2001-03Disconnect the oil pump control cable (10) and with-draw the cable from the wire guide (11).After withdrawing th

EngineRS 50ch. 33-6Release 00 2001-03WARNINGRemove all the clamps all the way along thecables and hoses.Prepare the same number of new clamps forrefit

RS 507Release 00 2001-03USED ENGINE OIL AND FORK OILUse latex glaves for the maintenance operations that require contact with used oil.Used oil may ca

EngineRS 50ch. 33-73Release 00 2001-03Unscrew and remove the 2 screws (36) and unscrewthe screw that holds the bracket on the back of thestarter motor

EngineRS 50ch. 33-8Release 00 2001-03Remove the two engine mounting bolts from the frame(39), and remove the washers and self-locking nutsfrom the opp

Fuel supply systemFuel supply systemRS 50ch. 44-14Release 00 2001-03

Fuel supply systemRS 50ch. 44-2Release 00 2001-03FUEL TANKThe fuel tank is equipped with a filler cap, and a fuel valve. The valve, as shown in the fi

Fuel supply systemRS 50ch. 44-34Release 00 2001-03Read carefully (PRECAUTIONS AND GENERALINFORMATION) and (FUEL).MAINTENANCETo service the tank, it ha

Fuel supply systemRS 50ch. 44-4Release 00 2001-03REMOVINGTHE FUEL VALVERaise up the tank (RAISING THE FUEL TANK).Remove the screws (1) and extract the

Fuel supply systemRS 50ch. 44-54Release 00 2001-03DESCRIPTION1)Choke2)Throttle valve3)Main jet4)Float5)Deflector tube kit6)Gaskets7)Valve cover8)Throt

Fuel supply systemRS 50ch. 44-6Release 00 2001-03REMOVINGTHE 2 STROKE OIL TANKRead carefully (PRECAUTIONS AND GENERALINFORMATION).Remove the rider and

Fuel supply systemRS 50ch. 44-74Release 00 2001-03Remove the clamp (3) and disconnect the tube (4)that delivers oil to the pump.To remove the two stro

Fuel supply systemRS 50ch. 44-8Release 00 2001-03NOTES

RS 508Release 00 2001-03BATTERY HYDROGEN GAS AND ELECTROLYTEThe battery gives off explosive gases; keep cigarettes, flames and sparks away from the ba

Cooling systemRS 50ch. 55-15Release 00 2001-03Cooling system

RS 50ch. 55-2Release 00 2001-03Cooling systemREMOVING THE RADIATORRead carefully (PRECAUTIONS AND GENERALINFORMATION) and (COOLANT).Remove the r.h sid

RS 50ch. 55-35Release 00 2001-03Cooling systemWARNINGPlug the ends of the hoses, to prevent foreignbodies from getting into them.NOTE Replace the rubb

RS 50ch. 55-4Release 00 2001-03Cooling systemNOTES

Electrical systemElectrical systemRS 50ch. 66-16Release 00 2001-03

Electrical systemRS 50ch. 66-2Release 00 2001-03INTRODUCTIONRead carefully (PRECAUTIONS AND GENERALINFORMATIONS) and (BATTERY).The information below w

Electrical systemRS 50ch. 66-36Release 00 2001-03MAIN WIRING DIAGRAMMAIN WIRING DIAGRAM KEY1) Generator2) Ignition coil3) Voltage regulator4) Rectifie

Electrical systemRS 50ch. 66-4Release 00 2001-03LOCATION OF COMPONENTSKEY1) Generator2) Ignition coil3) Voltage regulator4) Rectifier5) Battery6) Star

Electrical systemRS 50ch. 66-56Release 00 2001-03IGNITION CIRCUITLocation of components see (LOCATION OF COM-PONENTS).WIRING DIAGRAM1) Generator2) Coi

Electrical systemRS 50ch. 66-6Release 00 2001-03If the fault persists:Check the H.T. lead.Check the spark plug cap.Check the magneto flywheel (CHECKIN