1999–2010 Aprilia RS 50 Scooter Factory Service Manual (P/N 8140250)

• 250-page Aprilia PDF set: The RS 50 Workshop Manual is 200 pages, Release 00, first edition March 2001, and is marked 979 X, with cover code 8140250. The companion AM6 Workshop Manual is 50 pages, Release 00, first release January 2000, and is marked 970 X.
• Vehicle-level repair coverage includes scheduled maintenance, engine removal, fuel delivery, cooling, electrical diagnosis, bodywork, controls, exhaust, wheels, hydraulic brakes, front fork, steering, rear suspension, drive chain, and swingarm service.
• AM6 internal engine procedures cover cylinder-head, cylinder, piston, reed-valve, oil-mixer, stator, flywheel, starter, water-pump, clutch, gearbox, crankcase, crankshaft, selector, and transmission-shaft inspection, removal, reassembly, and functional checks.
• Electrical fault-finding is organized around a main wiring diagram, component-location view, circuit schematics, technical test data, and troubleshooting for ignition, charging and power supply, electric start, sensors, turn signals, horn, brake lights, and road lighting.
• Standard and Automatic Switch-on Device (ASD) lighting configurations receive separate light-circuit schematics, while designated-country switch assemblies and optional equipment are identified where applicable.
• Factory specifications and tooling include maintenance schedules, lubricant and fluid data, wear and clearance limits, adjustment data, system-specific torque tables, electrical checks, and Aprilia special-tool numbers.

Component and System Documentation

The vehicle manual documents the liquid-cooled, single-cylinder 49.75 cc two-stroke configuration with separate variable-rate oil injection, electric start, a wet multi-plate clutch, a six-speed gearbox, and a Dell'Orto SHA 14/12 carburetor. Its maintenance chapters cover battery and spark-plug service, air-cleaner and throttle adjustment, carburetor controls, gearbox oil, the two-stroke oil tank, coolant, brake-fluid replacement and bleeding, clutch and shift-lever adjustment, steering inspection, chain service, hose checks, and fastener inspection.

Engine access is handled in two levels. The RS 50 manual identifies the components that can be serviced with the engine still in the frame, including the carburetor, reed-valve assembly, cylinder head and cylinder, thermostat, water and oil pumps, clutch, flywheel, stator, pickup, and starter motor. It also covers complete downward engine removal from the frame. Internal repair is not duplicated in that vehicle chapter; it is supplied in the separate AM6 PDF included with this set.

Fuel-system coverage includes the tank, fuel-feed check, fuel valve, carburetor removal, the two-stroke oil tank, and a labeled SHA 14/12 carburetor exploded view with its specification table. Cooling-system information combines coolant service with radiator and filler-cap removal, thermostat inspection, water-pump repair, and assembly cautions intended to prevent trapped air.

AM6 Engine Repair Coverage

The AM6 manual goes well beyond routine top-end work. It covers power-unit teardown and inspection of the cylinder head, thermostat, cylinder, piston, rings, piston pin, gasket seats, and cylinder bore, followed by reassembly requirements. Separate sections address the intake manifold, reed valve, carburetor, oil mixer, flywheel magneto, stator, ignition timing, and starter motor.

The gearbox and clutch chapter covers crankcase separation, countershaft and selector removal, driving and driven shafts, crankshaft removal, gear-stack disassembly, shaft and bearing checks, end-play inspection, selector and desmodromic-shaft checks, transmission reassembly, gearshift-sequence testing, clutch assembly and position checks, oil-seal installation, and water-pump reassembly. Crankshaft and connecting-rod condition checks are included, but connecting-rod replacement is treated as specialist press work requiring dedicated equipment.

Two details show why the engine supplement matters during repair. For AM6 engines produced from 1995 onward, it calls out a changed installation direction for the clutch-side crankshaft oil seal. It also warns that incorrect piston-ring orientation can break the rings during cylinder installation.

Specification Highlights and Data Preview

The specifications are placed alongside the related repair sections. The RS 50 manual provides general ISO torque guidance plus assembly-specific fastener tables for chassis and service work. The AM6 supplement adds an engine torque table, lubricant chart, ignition-timing data, wear limits, clearances, end-play checks, and electrical resistance tests for the flywheel-magneto circuits.

Illustration coverage includes the Main Wiring Diagram, Location of Components, the standard and ASD Light Circuit schematics, the Dell'Orto carburetor exploded view, the AM6 ignition-timing drawing, and transmission gear-stack and clutch assembly views. Circuit sections pair diagrams with symptom-based troubleshooting and check procedures rather than leaving the wiring pages unexplained.

Special-tool information is equally specific. The chassis manual identifies support pin 8140204, rear stand 8705021, and swingarm adjustment socket 8101945. AM6 Tool Kit 8222355 is broken down into dedicated tools such as crankshaft extractor 8201525, crankshaft assembly tool 8201526, and clutch bell-housing spanner 8201527, with additional seal, flywheel, bearing, and engine-support tools identified in the manual.

Scope and Safe Shop Use

ASD coverage applies to the alternate lighting circuit; it is not presented as a separate engine, carburetor, or cooling-system build. This set is intended for machines matching the documented RS 50 chassis and electrical layout, Dell'Orto SHA 14/12 fuel system, and AM6 engine configuration.

Because these procedures involve gasoline, battery service, brake fluid, hot coolant, and suspended engine removal, repair work requires ventilation, controlled ignition sources, battery isolation, and stable support for the motorcycle and engine. Brake, steering, wheel, and suspension repair should be followed by the inspection and low-speed functional checks specified in the manuals before normal road use.