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1157 3

00/2003-12

RX 50 Racing

www.serviceaprilia.com

workshopmanual

8140763

UK

RX 50 Racing

INTRODUCTION

INTRODUCTION

0-1

INTRODUCTION

RX 50 Racing

SUMMARY
0.1. FOREWORD..................................................................................................................................................... 3 0.1.1. FOREWORD ............................................................................................................................................. 3 0.1.2. REFERENCE MANUALS .......................................................................................................................... 4 0.1.3. ABBREVIATIONS/SYMBOLS/CONVENTIONS ........................................................................................ 5

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RX 50 Racing 0.1.
0.1.1. -

INTRODUCTION

FOREWORD
FOREWORD This manual provides the information required for normal servicing. This publication is intended for use by aprilia dealerships and their qualified mechanics; many concepts have been omitted inasmuch as their inclusion would be superfluous for such an audience. Since complete mechanical explanations have not been included in this manual, the reader must be familiar with basic notions of mechanics, as well as with basic repair procedures. Without such familiarity, repairs and checks could be ineffective and even hazardous. Since the repair and vehicle check instructions are not exhaustive, special care must be taken to avoid damage and injury. To ensure maximum customer satisfaction with the vehicle, aprilia spa continuously improves its products and their documentation. The main technical modifications and changes in repair procedures are communicated to all aprilia dealerships and agencies worldwide. Such modifications will be entered in subsequent editions of the manual. In case of doubt regarding specific repairs or checks, contact the aprilia SERVICE DEPARTMENT; we will be pleased to provide all necessary information and assistance as well as keeping you updated on changes and modifications to the vehicle.

aprilia s.p.a. reserves the right to make changes to its products at any time, barring any such changes as may alter the essential features of a product as specified in the relevant manual. All rights of storage using electronic means, reproduction and total or partial adaptation, whatever the means adopted, are reserved in all countries. Third parties' products are only mentioned for information purposes, and constitute no engagement. aprilia s.p.a. is not liable in any way for the performance or use of these products. First edition: November 2003 Produced and printed by: DECA s.r.l. via Risorgimento, 23/1 - 48022 Lugo (RA) - Italy Tel. +39 - 0545 35235 Fax +39 - 0545 32844 E-mail: deca@decaweb.it www.decaweb.it on behalf of: aprilia s.p.a. via G. Galilei, 1 - 30033 Noale (VE) - Italy Tel. +39 (0)41 58 29 111 Fax +39 (0)41 58 29 190 www.aprilia.com www.serviceaprilia.com

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INTRODUCTION

RX 50 Racing

0.1.2.

REFERENCE MANUALS

PARTS CATALOGUES aprilia part# (description) 2193 OWNER'S MANUALS aprilia part# (description) 8202384 8202400 8202401

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RX 50 Racing
0.1.3. # < > ~ C F a.c A Ah API AT AV/DC bar DC cc CO CPU DIN DOHC ECU rpm HC ISC ISO kg kgm km km/h k kPa KS kW ABBREVIATIONS/SYMBOLS/CONVENTIONS = number = less than = greater than = less than or equal to = more than or equal to = approximately = infinity = degrees Celsius (centigrade) = degrees Fahrenheit = plus or minus = alternating current = Ampere = Ampere per hour = American Petroleum Institute = high voltage = Anti-Vibration Double Countershaft = pressure measurement (1 bar =100 kPa) = Direct Current = cubic centimetres = carbon monoxide = Central Processing Unit = German industrial standards (Deutsche Industrie Norm) = Double Overhead Camshaft = Electronic Control Unit = revolutions per minute = unburnt hydrocarbons = Idle Speed Control = International Standardization Organization = kilograms = kilogram metre (1 kgm = 10 Nm) = kilometres = kilometres per hour = kilo Ohm = kiloPascal (1 kPa = 0.01 bar) = clutch side (from the German "Kupplungseite") = kilowatt = litres = racetrack lap = Light Emitting Diode = left side = metres per second = maximum = millibar (1 mbar = 0.1 kPa) = miles = minimum = miles per hour = flywheel side (from the German "Magnetoseite") = MegaOhm = Not Available = Motor Octane Number = Research Octane Number = Newton metre (1 Nm = 0.1 kgm) = ohm = pick-up = Bottom Dead Centre = Top Dead Centre = Pneumatic Power Clutch

INTRODUCTION

LAP LED LEFT SIDE m/s max mbar mi MIN MPH MS M N.A. N.O.M.M. N.O.R.M. Nm PICK-UP BDC TDC PPC

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INTRODUCTION
RIGHT SIDE SAE TEST T.B.E.I. T.C.E.I. T.E. T.P. TSI UPSIDEDOWN V W

RX 50 Racing

= right side = Society of Automotive Engineers = diagnostic check = crown-head Allen screw = cheese-head Allen screw = hexagonal head = flat head screw = Twin Spark Ignition = inverted fork = volt = watt = diameter

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RX 50 Racing

GENERAL INFORMATION

GENERAL INFORMATION

1-1

GENERAL INFORMATION

RX 50 Racing

SUMMARY
1.1. STRUCTURE OF THE MANUAL...................................................................................................................... 3 1.1.1. CONVENTIONS USED IN THE MANUAL ................................................................................................. 3 1.1.2. SAFETY WARNINGS ................................................................................................................................ 4 1.2. GENERAL RULES............................................................................................................................................ 5 1.2.1. BASIC SAFETY RULES ............................................................................................................................ 5 1.3. DANGEROUS ELEMENTS............................................................................................................................... 8 1.3.1. WARNINGS ............................................................................................................................................... 8 1.4. RUNNING-IN .................................................................................................................................................. 12 1.4.1. RUNNING-IN ........................................................................................................................................... 12 1.5. VEHICLE IDENTIFICATION ........................................................................................................................... 13 1.5.1. POSITION OF THE SERIAL NUMBERS ................................................................................................. 13

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RX 50 Racing 1.1.
1.1.1.

GENERAL INFORMATION

STRUCTURE OF THE MANUAL


CONVENTIONS USED IN THE MANUAL

This manual is divided in sections and subsections, each covering a set of the most significant components. Refer to the index of sections when consulting the manual. Unless expressly specified otherwise, assemblies are reassembled by reversing the dismantling procedure. The terms "right" and "left" are referred to the rider seated on the vehicle in the normal riding position. Motorcycle operation and basic maintenance are covered in the "OWNER'S MANUAL". In this manual any variants are identified with these symbols: optional catalytic version MP SF all versions national certification European certification (EURO 1 limits)

VERSION: Italy United Kingdom Austria Portugal Finland

Greece Holland Switzerland Denmark Japan

Malaysia Chile Croatia Australia United States of America Brazil South Africa New Zealand Canada

Belgium Germany France Spain

Singapore Slovenia Israel South Korea

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GENERAL INFORMATION

RX 50 Racing

1.1.2.

SAFETY WARNINGS

The following precautionary warnings are used throughout this manual in order to convey the following messages: Safety warning. This symbol appears, whether in the manual or on the vehicle itself, to indicate a personal injury hazard. Non-compliance with the indications given in the messages preceded by this symbol may result in grave risks for you and other people's safety and for the vehicle! DANGER Indicates a potential hazard which may result in serious injury or even death. WARNING Indicates a potential hazard which may result in minor personal injury or damage to the vehicle. CAUTION The word "CAUTION" in this manual precedes important information or instructions.

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RX 50 Racing 1.2.
1.2.1.

GENERAL INFORMATION

GENERAL RULES
BASIC SAFETY RULES

CARBON MONOXIDE Should it be necessary to perform some operations with the vehicle running, make sure to work outdoors or in a wellaerated room. Avoid starting the engine indoors. In case you are working indoors, use a gas exhaust system. DANGER Exhaust gases contain carbon monoxide, which is extremely toxic if inhaled and may cause loss of consciousness or even lead to death by asphyxia. FUEL DANGER The fuel used to operate engines is highly flammable and becomes explosive under particular conditions. Refuelling and engine service should take place in a well-ventilated area with the engine stopped. Do not smoke when refuelling or in the proximity of sources of fuel vapours, avoid flames, sparks and any element that could ignite fuel or provoke explosions. DO NOT DISPOSE OF FUEL IN THE ENVIRONMENT. KEEP AWAY FROM CHILDREN. HIGH-TEMPERATURE COMPONENTS The engine and the exhaust system parts become hot and continue to be hot even for some time after the engine has been stopped. Before handling these parts, wear insulating gloves or wait for the engine and the exhaust system to cool completely down. USED GEARBOX AND FORK FLUIDS DANGER Wear latex gloves when servicing. Gear fluid may cause serious damage to the skin if handled daily and for long periods. Wash your hands carefully after use. Take it to the filling station where you usually buy it or to an oil salvage centre. Wear latex gloves when servicing. DO NOT DISPOSE OF OIL IN THE ENVIRONMENT KEEP AWAY FROM CHILDREN. BRAKE FLUID WARNING When handling the brake fluid, take care not to spill it on the plastic, rubber or painted parts, since it can damage them. When carrying out the maintenance operations on the braking system, use a clean cloth to cover these parts. Always wear safety goggles when working on the braking system. The brake fluid is highly irritant. Avoid contact with your eyes. If the brake fluid gets in contact with your eyes, carefully wash them with fresh water and immediately seek medical advice. KEEP AWAY FROM CHILDREN.

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GENERAL INFORMATION

RX 50 Racing

HYDROGEN GAS AND BATTERY ELECTROLYTE DANGER The battery electrolyte is a toxic, caustic substance containing sulphuric acid and thus able to cause severe burns in case of contact with the skin. Always wear tight gloves and protective clothes when handling this fluid. If the electrolyte gets in contact with the skin, carefully wash the parts of your body that get in contact with the fluid with abundant fresh water. Always use a protection for your eyes since even a very small amount of the battery fluid can cause blindness. In the event of contact with your eyes, carefully wash them with water for fifteen minutes and then immediately seek medical advice. Should you accidentally drink some fluid, drink abundant water or milk, then drink magnesia milk or vegetable oil and consult immediately a doctor. Battery releases explosive gases. Keep flames, sparks, cigarettes and any other heat source away from the battery. Make sure the room is well-aerated when servicing or recharging the battery. KEEP AWAY FROM CHILDREN. The battery fluid is corrosive. Do not spill it, especially on the plastic parts. Make sure that the electrolyte acid is suitable for the type of battery used. GENERAL PRECAUTIONS AND INFORMATION Follow these instructions closely when repairing, disassembling or reassembling the motorcycle or its components. DANGER Using bare flames is strictly forbidden when working on the motorcycle. Before servicing or inspecting the motorcycle: stop the engine and remove the key from the ignition switch; allow for the engine and exhaust system to cool down; where possible, lift the motorcycle using adequate equipment placed on firm and level ground. Be careful of any parts of the engine or exhaust system which may still be hot to the touch to avoid scalds or burns. Never put any mechanical parts or other vehicle components in your mouth when you have both hands busy. None of the motorcycle components is edible. Some components are harmful to the human body or toxic. Unless expressly specified otherwise, assemblies are reassembled by reversing the dismantling procedure. Where a procedure is cross-referred to relevant sections in the manual, proceed sensibly to avoid disturbing any parts unless strictly necessary. Never attempt to polish matte-finished surfaces with lapping compounds. Never use fuel instead of solvent to clean the motorcycle. Do not clean any rubber or plastic parts or the seat with alcohol, petrol or solvents. Clean with water and neutral detergent. Always disconnect the battery negative (-) lead before soldering any electrical components. When two or more persons service the same motorcycle together, special care must be taken to avoid personal injury. BEFORE DISASSEMBLING ANY COMPONENTS Clean off all dirt, mud, and dust and clear any foreign objects from the vehicle before disassembling any components. Use the model-specific special tools where specified.

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RX 50 Racing

GENERAL INFORMATION

DISASSEMBLING THE COMPONENTS Never use pliers or similar tools to slacken and/or tighten nuts and bolts. Always use the suitable spanner. Mark all connections (hoses, wiring, etc.) with their positions before disconnecting them. Identify each connection using a distinctive symbol or convention. Mark each part clearly to avoid confusion when refitting. Thoroughly clean and wash any components you have removed using a detergent with low flash point. Mated parts should always be refitted together. These parts will have seated themselves against one another in service as a result of normal wear and tear and should never be mixed up with other similar parts on refitting. Certain components are matched-pair parts and should always be replaced as a set. Keep away from heat sources. REASSEMBLING THE COMPONENTS DANGER Never reuse a circlip or snap ring. These parts must always be renewed once they have been disturbed. When fitting a new circlip or snap ring, take care to move the open ends apart just enough to allow fitment to the shaft. Make it a rule to check that a newly-fitted circlip or snap ring has located fully into its groove. Never clean a bearing with compressed air. CAUTION All bearings must rotate freely with no hard spots or noise. Replace any bearings that do not meet these requirements. Use ORIGINAL aprilia SPARE PARTS only. Use the specified lubricants and consumables. Where possible, lubricate a part before assembly. When tightening nuts and bolts, start with the largest or innermost nut/bolt and observe a cross pattern. Tighten evenly, in subsequent steps until achieving the specified torque. Replace any self-locking nuts, gaskets, seals, circlips or snap rings, O-rings, split pins, bolts and screws which have a damaged thread. Lubricate the bearings abundantly before assembly. Make it a rule to check that all components you have fitted are correctly in place. After repairing the motorcycle and after each service inspection, perform the preliminary checks, and then operate the motorcycle in a private estate area or in a safe area away from traffic. Clean all mating surfaces, oil seal edges and gaskets before assembly. Apply a thin layer of lithium grease along the edges of oil seals. Fit oil seals and bearings with the marking or serial number facing outwards (in view). ELECTRICAL CONNECTORS To disconnect the electrical connectors, follow the procedures below. Failure to comply with these procedures may lead to irreparable damage to the connector and the wiring as well. If present, press the special safety hooks. WARNING Do not pull cables to disconnect the two connectors. Grasp the two connectors and disconnect them by pulling them in the two opposite directions. In case of dirt, rust, moisture, etc.., thoroughly clean the inside of the connectors with compressed air. Make sure that the cables are correctly fitted inside the connector terminals. CAUTION The two connectors have just one correct positioning. Make sure to position them in the right direction. Then fit the two connectors. Make sure they are correctly coupled (a click will be heard if hooks are present). TIGHTENING TORQUE SETTINGS DANGER Always remember that the tightening torque settings of all wheel, brake, wheel shaft and other suspension parts play a fundamental role to ensure vehicle safety. Make sure that these values are always within the specified limits. Check fastening parts tightening torque settings at regular intervals. Upon reassembly, always use a torque wrench. Failure to comply with these recommendations could lead to the loosening and detachment of one of these parts with a consequent locking of the wheel or other serious troubles affecting the vehicle manoeuvrability, and thus the risk of falls and serious injuries or death.

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GENERAL INFORMATION

RX 50 Racing

1.3.
1.3.1. FUEL

DANGEROUS ELEMENTS
WARNINGS

DANGER The fuel used to operate engines is highly flammable and becomes explosive under particular conditions. Refuelling and engine service should take place in a well-ventilated area with the engine stopped. Do not smoke when refuelling or in the proximity of sources of fuel vapours, avoid flames, sparks and any element that could ignite fuel or provoke explosions. Take care not to spill fuel out of the filler, or it may ignite when in contact with hot engine parts. In the event of accidental fuel spillage, make sure the affected area is fully dry before starting the engine. Fuel expands from heat and when left under direct sunlight. Never fill the fuel tank up to the brim.Tighten the filler cap securely after each refuelling. Avoid contact with skin. Do not inhale vapours. Do not swallow fuel. Do not transfer fuel between different containers using a hose. DO NOT DISPOSE OF FUEL IN THE ENVIRONMENT. KEEP AWAY FROM CHILDREN. Use only premium grade unleaded petrol, min. O.N. 95 (N.O.R.M.) and 85 (N.O.M.M.). LUBRICANTS DANGER A good lubrication ensures the vehicle safety. Failure to keep the lubricants at the recommended level or the use of a non-suitable new and clean type of lubricant can lead to the engine or gearbox seizure, thus causing serious accidents, personal injury or even death. Gear fluid may cause serious damage to the skin if handled daily and for long periods. Wash your hands carefully after use. Do not dispose of oil in the environment. Take it to the filling station where you usually buy it or to an oil salvage centre. WARNING When filling the vehicle with this oil, take care not to spill it out. Immediately clean spilt oil, or it might damage the vehicle paintwork. In case of contact with oil, the tyres surface will become very slippery, thus becoming a serious danger for your safety. In case of leaks, do not use the vehicle. Check and trace the cause of leaks and proceed to repair. GEARBOX FLUID DANGER Gear fluid may cause serious damage to the skin if handled daily and for long periods. Wash your hands carefully after use. Do not dispose of oil in the environment. Dispose of engine oil through the nearest waste oil reclamation firm or through the supplier. Wear latex gloves when servicing. FRONT FORK FLUID DANGER Front suspension response can be modified to a certain extent by changing damping settings and/or selecting a particular grade of oil. Standard oil grade is: SAE 20 W. Different oil grades can be selected to obtain a particular suspension response (choose SAE 5W for a softer suspension, 20W for a stiffer suspension). The two grades can also be mixed in varying solutions to obtain the desired response.

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RX 50 Racing
BRAKE FLUID

GENERAL INFORMATION

CAUTION This vehicle is fitted with front and rear disc brakes. Each braking system is operated by an independent hydraulic circuit. The information provided below applies to both braking systems. DANGER Do not use the vehicle in case brakes are worn out or do not work properly. The brakes are the parts that most ensure your safety and for this reason they must always be perfectly working. Failure to comply with these recommendations will probably lead to a crash or an accident, with a consequent risk of personal injury or death. A wet surface reduces brakes efficiency. DANGER In case of wet ground the braking distance will be doubled, since both brakes and tyre grip on the road surface are extremely reduced by the water present on the road surface. Any water on brakes, after washing the vehicle or driving on a wet road surface or crossing puddles or gips, can wet brakes so as to greatly reduce their efficiency. Failure to comply with these recommendations may lead to serious accidents, with a consequent risk of severe personal injuries or death. Brakes are critical safety components. Do not ride the vehicle in case brakes are not working at their best. Check for brakes proper operation before every trip. Brake fluid is an irritant. Avoid contact with eyes or skin. In the event of accidental contact, wash affected body parts thoroughly. In the event of accidental contact with eyes, contact an eye specialist or seek medical advice. DO NOT RELEASE BRAKE FLUID INTO THE ENVIRONMENT. KEEP AWAY FROM CHILDREN. When handling brake fluid, take care not to spill it onto plastic or paint-finished parts or they will damage. DANGER Do not use any brake fluids other than the specified type. Never mix different types of fluids to top up level, as this will damage the braking system. Do not use brake fluid from containers which have been kept open or in storage for long periods. Any sudden changes in play or hardness in the brake levers are warning signs of problems with the hydraulic circuits. Ensure that the brake discs and brake linings have not become contaminated with oil or grease. This is particularly important after servicing or inspections. Make sure the brake lines are not twisted or worn. Prevent accidental ingress of water or dust into the circuit. Wear latex gloves when servicing the hydraulic circuit.
DISC BRAKES

DANGER The brakes are the parts that most ensure your safety and for this reason they must always be perfectly working; check them before every trip. A dirty disc soils the pads. Dirty pads must be replaced, while dirty discs must be cleaned with a high-quality degreaser. Perform the maintenance operations with half the indicated frequency if the vehicle is used in rainy or dusty areas, on uneven surfaces or for racing. Check brake pads for wear. When the brake pads wear out, the level of the fluid decreases to automatically compensate for their wear. The front brake fluid reservoir is located on the right handlebar, near the front brake lever. The rear brake fluid reservoir is located under the right fairing. Do not use the vehicle if the braking system leaks fluid.

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GENERAL INFORMATION
COOLANT

RX 50 Racing

DANGER Coolant is toxic when ingested and is an irritant, contact with eyes or skin may cause irritation. In the event of contact with your skin or eyes, rinse repeatedly with abundant water and seek medical advice. In the event of ingestion, induce vomiting, rinse mouth and throat with abundant water and seek medical advice immediately. DO NOT RELEASE INTO THE ENVIRONMENT. KEEP AWAY FROM CHILDREN. DANGER Take care not to spill coolant onto hot engine parts. It may ignite and produce invisible flames. Wear latex gloves when servicing. Do not ride when coolant is below the minimum level. Coolant mixture is a 50% solution of water and antifreeze. This is the ideal solution for most operating temperatures and provides good corrosion protection. This solution is also suited to the warm season, as it is less prone to evaporative loss and will reduce the need for topups. In addition, less water evaporation means fewer minerals salts depositing in the radiator, which helps preserve the efficiency of the cooling system. When the temperature drops below zero degrees centigrade, check the cooling system frequently and add more antifreeze (up to 60% maximum) to the solution, if needed. Use distilled water in the coolant mixture. Tap water will damage the engine. Refer to the chart given below and add water with the quantity of antifreeze to obtain a solution with the desired freezing point: Freezing point C -20 -30 -40 Coolant % of volume 35 45 55

CAUTION Coolants have different specifications. The protection degree is written on the label. WARNING Use nitrite-free coolant only, with a protection until at least -35C. DRIVE CHAIN Check drive chain operation, wear, slack and lubrication at regular intervals. The vehicle is equipped with an endless chain with a joint link. WARNING If too slack, the chain can come off the front or rear sprockets thus leading to serious accidents and damage to the vehicle, with consequent serious personal injury or death. Do not use the vehicle if the chain slack has not been correctly adjusted. To check the chain, take it with your hand where it turns on the rear sprocket and pull it as to separate it from the sprocket itself. If you can move the chain apart of the front sprocket for more than 3 mm (0.125 in), change chain, front and rear sprocket. DANGER If not properly maintained, chain can early wear out and lead to the damage of both front and rear sprockets. Perform chain maintenance operations more frequently if the vehicle is used on rainy or dusty areas.

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RX 50 Racing
TYRES

GENERAL INFORMATION

WARNING If tyres are excessively inflated, the vehicle will be hard, difficult and uncomfortable to ride. In addition, the roadworthiness, mainly on wet surfaces and during cornering, will be impaired. Flat tyres (insufficient pressure) can slip on the rim and make you lose the control of the vehicle. In this case too, both vehicle roadworthiness, manoeuvrability and brake efficiency will be impaired. Tyres changing, repair, maintenance and balancing must be carried out by specialized technicians using suitable equipment. When new, tyres can have a thin slippery protective coating. Drive carefully for the first kilometres (miles). Never use rubber treating substances on tyres. In particular, avoid contact with fluid fuels, leading to a rapid wear. In case of contact with oil or fuel, do not clean but change the tyres. DANGER Some of the factory-assembled tyres of this vehicle are provided with wear indicators. There are several kinds of wear indicators. For more information on how to check the wear, contact your Dealer. Visually check if the tyres are worn and in this case have them changed. If a tyre deflates while driving, stop immediately. Avoid hard brakings or moves and do not close throttles too abruptly. Slowly close the throttle grip, move to the edge of the road and use the engine brake to slow down until coming to a halt. Failure to comply with these recommendations may lead to accidents, with a consequent risk of personal injuries or death. Do not install tyres with air tube on rims for tubeless tyres and vice versa.

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GENERAL INFORMATION

RX 50 Racing

1.4.
1.4.1.

RUNNING-IN
RUNNING-IN

The running-in of the engine is essential to ensure its life-span and trouble-free operation. If possible, drive on hilly roads and/or roads with many bends, so that the engine, the suspensions and the brakes undergo a more effective running-in. During running-in, change speed. In this way the components are first "loaded" and then "relieved" and the engine parts can thus cool down. Even if it is important to stress the engine components during running-in, take care not to exceed. Keep to the following indications: Do not open the throttle completely if the speed is low, both during and after the running-in. During the first 100 km (62 mi) pull the brakes with caution, avoiding sharp and prolonged brakings. This ensures a correct bedding-in of the pads on the brake discs. CAUTION After the first month of operation, carry out the checks indicated in the column "After running-in", see (SCHEDULED MAINTENANCE CHART), in order to avoid hurting yourself or other people and/or damaging the vehicle.

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RX 50 Racing 1.5.
1.5.1.

GENERAL INFORMATION

VEHICLE IDENTIFICATION
POSITION OF THE SERIAL NUMBERS

These numbers are necessary for the registration of the vehicle. CAUTION Do not alter the identification numbers if you do not want to incur severe penal and administrative sanctions; in particular, altering the frame number voids the warranty. FRAME NUMBER The frame number is stamped on the right hand side of the headstock.

ENGINE NUMBER The engine number is stamped over the front sprocket guard.

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RX 50 Racing

GENERAL TECHNICAL INFORMATION

GENERAL TECHNICAL INFORMATION

2-1

GENERAL TECHNICAL INFORMATION

RX 50 Racing

SUMMARY
2.1. GENERAL TECHNICAL INFORMATION ......................................................................................................... 3 2.1.1. TECHNICAL DATA.................................................................................................................................... 3 2.1.2. TIGHTENING TORQUE SETTINGS ......................................................................................................... 5 2.1.3. LUBRICANT TABLE .................................................................................................................................. 7 2.1.4. SPECIAL TOOLS ...................................................................................................................................... 8

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RX 50 Racing 2.1.
2.1.1.

GENERAL TECHNICAL INFORMATION

GENERAL TECHNICAL INFORMATION


TECHNICAL DATA 2065 mm 820 mm 940 mm 1200 mm 350 mm 104 kg 1390 mm AM6 2-stroke with reed intake 1 49.75 cu. cm 40.3 mm /39 mm 12.0 0.5: 1 Kick starter 1600 100 rpm Alloy multiplate wet clutch Front clutch dogs, 6 gears Separated Liquid cooling with forced circulation -17 C 9.5 l 1.5 l 1.3 l 0.5 l 820 cu. cm 2 (in the countries where a passenger is allowed) 400 cu. cm 75+30 kg 0.9 l (60% antifreeze+40% water) Helical gears. Ratio : 3.55 (Z=20/71) Chain, 1 / 2 x 3.16 = roller 7.75 mm. Ratio : 4.25 (Z=11/51) DellOrto PHBN 16 Diameter equivalent to 16 mm 80 32 40 45 212 GA A13 2nd notch 3.5 g 1+1/4 Premium-grade unleaded petrol, minimum octane rating 95 (ROM) and 85 (MON), DIN 51607. Premium-grade unleaded petrol, minimum octane rating 95 (ROM) and 85 (MON), DIN 51607. High-resistance single-beam frame, split above the exhaust. 26 Steel swinging arm featuring rectangular section, fitted onto friction-proof bushes.

DIMENSIONS Max. length Max. width Seat height Max. height (handlebar height) Minimum ground clearance Weight in running order Wheelbase ENGINE Model Type Number of valves Number of cylinders Total displacement Bore/stroke Compression ratio Starting Engine idling speed Clutch Gearbox Lubricating system Cooling system Minimum operating temperature CAPACITIES Fuel (including reserve) Reserve (mechanically operated) Mixer oil tank capacity Reserve (with light on instrument panel) Gearbox fluid Seat Fork fluid (each leg) Vehicle max. load (rider + luggage) Cooling circuit TRANSMISSION SYSTEM Primary Final CARBURETTOR Model Choke Main nozzle Idle nozzle Throttle valve Starter nozzle Atomizer Tapered needle Float Air screw turns (from completely closed position) FUEL SYSTEM Fuel (running-in 500 Km) Fuel (after running-in) FRAME Type Steering head angle SWINGING ARM Type

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GENERAL TECHNICAL INFORMATION


SUSPENSIONS Front Travel Rear Travel Rear wheel travel BRAKES Front Rear WHEEL RIMS Type Front Rear TYRES Front Rear INFLATING PRESSURE Front (off-road) (rider only) Front (off-road) (rider + passenger) Front (mixed road) (rider only) Front (mixed road) (rider + passenger) Front (paved road) (rider only) Front (paved road) (rider + passenger) Rear (off-road) (rider only) Rear (off-road) (rider + passenger) Rear (mixed road) (rider only) Rear (mixed road) (rider + passenger) Rear (paved road) (rider only) Rear (paved road) (rider + passenger) IGNITION Type Spark advance SPARK PLUG Standard Spark plug electrode gap ELECTRIC SYSTEM Battery Fuses Generator power Regulator output voltage Flywheel maximum voltage Pick-up check BULBS Low/high beam Front parking light Direction indicators bulb Rear parking lights / stop bulb Instrument panel lights

RX 50 Racing
Upside-down, 40 mm fork legs 260 mm Gas monoshock with adjuster 100 mm 260 mm Disc brake - 250 mm, hydraulically operated, floating calliper featuring two parallel 25 mm pistons. Disc brake - 220 mm, hydraulically operated, fixed calliper featuring two opposite 28 mm pistons. Aluminium, spoke rims 1.6 x 21 1.85 x 18 80 / 90 x 21" Enduro-type 110 / 80 x 18" Enduro-type 130 Kpa (1.3 bar) 150 Kpa (1.5 bar) 150 Kpa (1.5 bar) 170 Kpa (1.7 bar) 160 Kpa (1.6 bar) 180 Kpa (1.8 bar) 140 Kpa (1.4 bar) 160 Kpa (1.6 bar) 160 Kpa (1.6 bar) 180 Kpa (1.8 bar) 180 Kpa (1.8 bar) 200 Kpa (2.0 bar) Electronic 1.5 mm corresponding to 20 before TDC. NGK BR9ES 0.6 - 0.7 mm 12 V 4 Ah 7.5 A 95 W 13/15 V > 40 V 125 10% ohm 12 V 35/35 W 12 V 3 W 12 V 10 W 12 V 5 / 21 W 12 V 2 W

2-4

RX 50 Racing
2.1.2. TIGHTENING TORQUE SETTINGS

GENERAL TECHNICAL INFORMATION

COMPONENT

Torque (Nm) ENGINE Engine-to-frame fastening

Notes

Front fastener Upper and lower rear fastener Front sprocket cover Mixer cover Cable fastener on engine Starting lever Gearchange lever Engine clutch adjuster Sleeve clamp, air box side Sleeve clamp, engine side Swinging arm shaft Chain guard Rear chain guide Chain sliding shoe Side stand screw Side stand nut Fork leg to top plate fastener Fork leg to bottom plate fastener Hub Steering tube nut Steering ring nut Fork leg guard

25 25 Parts fastened to the engine 3 3 7 10 12 7 CARBURETTOR 3 3 SWINGING ARM 100 7 10 25 SIDE STAND 10 35 FRONT FORK 25 10 10 80 10 3 REAR SUSPENSION Shock absorber

Lubricate Lubricate and apply Loctite 243 Lubricate and apply Loctite 243 -

Shock absorber Single connecting rod Double connecting rod Battery negative cable Key ignition switch Headlight Tail light Front direction indicators bulb Coil

50 Connecting rods 50 50 ELECTRIC SYSTEM 10 25 1 5 3 10

2-5

GENERAL TECHNICAL INFORMATION


FRONT WHEEL Wheel shaft nut Wheel shaft nut Radiator cowling Radiator 80 REAR WHEEL 100 COOLING SYSTEM 5 5 BRAKING SYSTEMS Front system Front brake calliper Front brake line guide Rear brake calliper Rear brake lever Rear brake master cylinder Rear brake master cylinder guard Rear brake fluid reservoir Silencer Muffler Silencer clamp Fuel tank - RH and LH side Fuel tank - rear Fuel cock Tool bag Front mudguard cat's eye Tail guard Air scoops Side panels Helmet lock Rider footpeg Instrument panel support plate Shock absorber guard Number plate holder-to-frame Seat Oil reservoir Passenger footpeg support Handlebar Clutch lever Throttle control dowel Dimmer switch Throttle control Air box-to-frame Air box cover 25 4 Rear system 25 50 10 10 3 EXHAUST SYSTEM 25 10 15 FUEL TANK 10 25 7 FRAME / OUTER STRUCTURES 5 1 7 5 5 10 20 10 3 5 10 3 25 HANDLEBAR AND CONTROLS 17 10 1 1 2 AIR BOX 3 2 Lubricate Lubricate

RX 50 Racing

2-6

RX 50 Racing
2.1.3. LUBRICANT TABLE PRODUCT

GENERAL TECHNICAL INFORMATION

LUBRICANT Gearbox fluid

RECOMMENDED: F.C., SAE 75W 90 GEAR SYNTH, SAE 75W - 90. As an alternative to recommended oils, top brand oils meeting or exceeding GL-4 A.P.I. specifications can be used. RECOMMENDED: GREEN HIT 2 CITY 2T. As an alternative to recommended oils, top brand oils meeting or exceeding ISO L ETEC++, A.P.I.TC++ specifications can be used. RECOMMENDED: F.A. 5W or F.A. 20W FORK 5W ou bien FORK 20W. When you wish to obtain an intermediate response between those offered by F.A. 5W and F.A. 20W FORK 5W ou bien FORK 20W, you may mix the different products as follows: SAE 10W = F.A. 5W 67% of volume + F.A. 20W 33% of volume FORK 5W 33% ou bien FORK 20W 67%. F.A. 5W 33% of volume, + F.A. 20W 67% of volume SAE 15W = FORK 5W 33% ou bien FORK 20W 67%.

Mixer oil

Front fork fluid

Bearings and other lubrication points

Battery terminals Chain spray grease Brake fluid

RECOMMENDED: AUTOGREASE MP GREASE 30. As an alternative to recommended grease, use top brand rolling bearing grease that will resist a temperature range of -30C - +140C, with dropping point 150C - 230C, high corrosion protection, good resistance to water and oxidisation. Use neutral grease or Vaseline. RECOMMENDED: CHAIN SPRAY CHIAN LUBE CAUTION Use new brake fluid only. Do not mix different makes or types of oil without having checked bases compatibility. The brake system is filled with BRAKE 5.1 DOT 4. F.F. DOT 4 (compatible DOT 5) -

Engine coolant

CAUTION Use only nitrite-free antifreeze and corrosion inhibitors with a freezing point of -35C as a minimum. RECOMMENDED: ECOBLU 40 C COOL.

2-7

GENERAL TECHNICAL INFORMATION

RX 50 Racing

2.1.4.

SPECIAL TOOLS

In order to perform assembly, reassembly and settings correctly, special tools suitable for the task must be used. The use of special tools avoids the potential risk of damage as a result of inappropriate tools and/or improvised methods. Below is a list of the special tools designed especially for this specific vehicle. If necessary, request the multi-purpose special tools. WARNING Before using the special tools, consult any documents attached.

Pos. 1

aprilia part# (tool description and function) 8140192 (Tool to remove / reassemble the chain)

2-8

RX 50 Racing

SCHEDULED MAINTENANCE

SCHEDULED MAINTENANCE

3-1

SCHEDULED MAINTENANCE

RX 50 Racing

SUMMARY
3.1. SCHEDULED MAINTENANCE......................................................................................................................... 3 3.1.1. INTRODUCTION ....................................................................................................................................... 3 3.1.2. SCHEDULED MAINTENANCE CHART .................................................................................................... 4 3.2. BRAKE FLUID .................................................................................................................................................. 5 3.2.1. CHECKING AND BLEEDING THE FRONT AND REAR BRAKE .............................................................. 5 3.3. DRIVE CHAIN................................................................................................................................................... 6 3.3.1. CHECKING THE CHAIN............................................................................................................................ 6 3.3.2. LUBRICATING THE CHAIN ...................................................................................................................... 7 3.3.3. ADJUSTING THE CHAIN .......................................................................................................................... 8

3-2

RX 50 Racing 3.1.
3.1.1.

SCHEDULED MAINTENANCE

SCHEDULED MAINTENANCE
INTRODUCTION

In order to keep your vehicle in sleek running order, aprilia recommends that you respect the intervals specified for the scheduled maintenance of every component. This section deals with the scheduled maintenance procedures for the main vehicle components. DANGER Before servicing or inspecting the motorcycle: stop the engine and remove the key from the ignition switch; allow for the engine and exhaust system to cool down; where possible, lift the motorcycle using adequate equipment placed on firm and level ground. Be careful of any parts of the engine or exhaust system which may still be hot to the touch to avoid scalds or burns. None of the motorcycle components is edible. Never bite, suck, chew or ingest any of the motorcycle components for any reason whatsoever. Unless expressly specified otherwise, motorcycle assemblies are refitted or reassembled by reversing the removal or dismantling procedure.

3-3

SCHEDULED MAINTENANCE

RX 50 Racing

3.1.2. Parts

SCHEDULED MAINTENANCE CHART After runningin (after 1 month) 1 1 2 Every 12 months 1 1 Every 3 months: 2 Every 6 months: 3 1 1 1 1 1 1 1 1 2 2 1 1 Every 24 months

Rear shock absorber Transmission and control cables Battery Clamp tightening - Electrolyte level SPARK PLUG Idling speed CARBURETTOR Wheel truing Steering tube bearings and play Wheel bearings * Brake discs Mixer oil filter Vehicle overall operation Braking systems Cooling system Muffler/exhaust silencer Air cleaner * Light system Brake fluid Coolant Mixer oil level Gearbox fluid Headlight setting - operation Wheels/Tyres and inflating pressure Tightening of nuts and bolts Tightening of battery clamps Mixer oil reserve light Spoke tension Final drive (chain, rear and front sprockets) Front fork fluid and oil seal Piston and piston rings Fuel pipe Mixer oil pipe Clutch wear Drive chain slack and lubrication * Front and rear brake pads wear *

4 1 1 1 1 1 1 1 Every year: 3 Every 2 years:3 Check before each ride 3 1 1 1 1 1 1 1 1 1 1 1 1 1 Every 2 years: 3 Every 2 years: 1 Every 4 years: 3 1 1 Every month: 1 1 Every month: 1

2 2 -

3 -

Every 4 years: 3 Every 4 years: 3 1

1 = check and clean, adjust, lubricate or replace, if necessary; 2 = clean; 3 = replace; 4 = adjust. * = always to be performed in case of off-road use. Decrease the maintenance intervals if the vehicle is used in rainy or dusty conditions, on rough roads or for racing. ( ) = OPERATIONS THAT CAN BE CARRIED OUT BY THE USER

3-4

RX 50 Racing 3.2.
3.2.1.

SCHEDULED MAINTENANCE

BRAKE FLUID
CHECKING AND BLEEDING THE FRONT AND REAR BRAKE

This vehicle is fitted with hydraulically operated front and rear disc brakes. Periodically check fluid level in the master cylinder reservoir. After the first 500 km or in the event of an increase in the lever free play, it is necessary to bleed the hydraulic system to expel any air. CAUTION The bleeding procedure is the same for the front and rear systems.

WARNING Remove the right-hand side body panel, see 5.1.1 (REMOVING THE OUTER STRUCTURES) to gain access to the rear brake fluid reservoir. Remove the calliper (1) bleed valve cap. Fit the end of a clear hose (2) to the calliper (1) bleed valve. Place the other end of the clear hose (2) inside a container (3). Remove the brake fluid reservoir cover and check that the fluid is at the maximum level; top up, if needed, see 2.3.1 (LUBRICANT TABLE).

Slowly pull (2-3 times) the brake lever; keep it pulled, loosen the bleed valve (1) until fluid starts coming out of the hose together with any air. Tighten the bleed valve and release the brake lever. Repeat the above procedure until no air can be seen in the fluid coming out of the valve. Tighten the valve, remove the hose, make sure not to soil brake pads and disc. Refit the cap, top up up to maximum level with the brake fluid recommended under LUBRICANT TABLE and close the cap.

WARNING Repeatedly pull the front brake lever and check that brakes are operating correctly. The brake fluid is corrosive and might cause damage. Never reuse bled fluid.

3-5

SCHEDULED MAINTENANCE

RX 50 Racing

3.3.
3.3.1.

DRIVE CHAIN
CHECKING THE CHAIN

Check chain for wear and make sure there are no hard spots, slack or seized links. If there are, change the chain. WARNING Never fit a new drive chain onto front/rear sprockets having worn teeth and never use a used chain on new front/rear sprockets.

REAR WHEEL SHAFT POSITION 1 new bike 2 drive system is to be replaced

3-6

RX 50 Racing
3.3.2. LUBRICATING THE CHAIN

SCHEDULED MAINTENANCE

Lubricate the chain frequently (see 2.1.3 LUBRICANT TABLE), approximately every 4000 km or more frequently if the motorcycle is used in rainy or dusty conditions or on rough roads.

3-7

SCHEDULED MAINTENANCE

RX 50 Racing

3.3.3.

ADJUSTING THE CHAIN Place the vehicle on a safe support so that the rear wheel is not touching the ground and the rear suspension is completely uncompressed. Check that deflection of the lower section of the chain midway between the sprockets is approx. 30-35 mm.

If not so, proceed as follows: Loosen the wheel shaft nut (1).

Move the chain tensioners (2).

DANGER Wheel truing. Check that the fixed reference mark on swinging arm (3) is lined up with the same chain tensioner number on each side.

3-8

RX 50 Racing
Once finished, tighten the rear wheel shaft nut (1) to the specified torque. Rear wheel shaft nut tightening torque: 100 Nm.

SCHEDULED MAINTENANCE

3-9

RX 50 Racing

ENGINE

ENGINE

4-1

ENGINE

RX 50 Racing

SUMMARY
4.1. ENGINE ............................................................................................................................................................ 3 4.1.1. REMOVING THE ENGINE FROM THE FRAME ....................................................................................... 3 4.1.2. REFITTING THE ENGINE TO THE FRAME. .......................................................................................... 16 4.1.3. TIGHTENING TORQUE SETTINGS ....................................................................................................... 29 4.2. ENGINE OUTER COMPONENTS .................................................................................................................. 30 4.2.1. REMOVING ENGINE OUTER COMPONENTS ...................................................................................... 30 4.2.2. TIGHTENING TORQUE SETTINGS ....................................................................................................... 33

4-2

RX 50 Racing 4.1.
4.1.1.

ENGINE

ENGINE
REMOVING THE ENGINE FROM THE FRAME Remove the seat nut.

Remove the seat.

Remove the two elastic bands securing the air scoops.

4-3

ENGINE
On both sides, loosen the two screws joining the scoops to the radiator cowling.

RX 50 Racing

On both sides, loosen the two side screws securing the scoops to the fuel tank.

4-4

RX 50 Racing
Remove the air scoops.

ENGINE

Loosen the central screw securing the fuel tank to the frame.

On both sides, loosen the two fuel tank side screws.

Disconnect the breather hose on the cap.

4-5

ENGINE
Close the fuel cock and disconnect the fuel hose.

RX 50 Racing

Remove the fuel tank.

Remove the outer structures, then remove the engine from the frame. Loosen the clamp securing the silencer to the muffler.

4-6

RX 50 Racing
Release the two cylinder springs.

ENGINE

Release the secondary air pipe clamp and remove the pipe.

4-7

ENGINE
Loosen the screw securing the muffler to the frame and remove it.

RX 50 Racing

Loosen the screw with copper washer from water pump cover and drain all coolant from the cooling system. Loosen the radiator plug so that coolant will drain easily.

Release hose clamp and remove radiator pipe from water pump.

4-8

RX 50 Racing

ENGINE

Release the hose clamp and remove the radiator pipe from the cylinder head.

Release the hose clamps and remove the carburettor heating pipes from cylinder head.

4-9

ENGINE

RX 50 Racing

Loosen the oil pump cover screw and remove the cover.

4 - 10

RX 50 Racing

ENGINE

Disconnect the oil pump drive cable.

Loosen the securing screw and remove the earth wire from the intake manifold.

Disconnect the clutch cable from the lever on crankcase.

4 - 11

ENGINE
Loosen and remove the oil pump screws.

RX 50 Racing

Remove the oil pump.

Loosen the clamp securing the carburettor to the intake manifold.

Loosen the clamp securing the carburettor to the air box.

4 - 12

RX 50 Racing
Detach the carburettor from the engine.

ENGINE

Remove the spark plug cap.

Loosen the securing screw and disconnect the neutral indicator light connector.

Disconnect the three generator wiring connections from the coil.

4 - 13

ENGINE
Disconnect the generator wiring connector from the voltage regulator.

RX 50 Racing

Loosen the two screws and remove the front sprocket guard.

Remove the front sprocket circlip.

Remove the front sprocket with the chain in position.

4 - 14

RX 50 Racing
Remove the front sprocket from the chain.

ENGINE

Remove the two rear pins securing the engine to the frame.

Remove the front pin securing the engine to the frame.

Remove the engine from the vehicle left side.

4 - 15

ENGINE

RX 50 Racing

4.1.2.

REFITTING THE ENGINE TO THE FRAME. Fit the engine to the frame.

Fit the three engine securing pins and tighten them to the specified torque (25 Nm).

Wrap the chain around the front sprocket and fit it to the engine.

4 - 16

RX 50 Racing
Fit the front sprocket circlip.

ENGINE

Fit the front sprocket guard and tighten the two securing screws.

Connect the generator wiring in this order: Yellow cable to voltage regulator.

White, red and green cable to the coil.

4 - 17

ENGINE
Fit the neutral indicator light connector and tighten the securing screw.

RX 50 Racing

Fit the spark plug cap.

Fit the carburettor to the intake manifold and to the air box opening.

Tighten the clamps on the intake manifold and on the air box opening.

4 - 18

RX 50 Racing

ENGINE

Fit the oil pump and tighten the two securing screws.

Connect the clutch cable to the clutch control lever on the crankcase.

Position the earth wire to the intake manifold, fit the clutch cable stop plate and tighten the securing screw.

4 - 19

ENGINE
Connect the oil pump drive cable.

RX 50 Racing

Fit the oil pump cover and tighten the two securing screws.

Connect the carburettor heating pipes to the cylinder head and tighten the relevant clamps.

4 - 20

RX 50 Racing

ENGINE

Connect the radiator pipe to the water pump and tighten the relevant clamp.

4 - 21

ENGINE

RX 50 Racing

Connect the radiator pipe to the cylinder head and tighten the relevant clamp.

Tighten the water drain screw onto water pump cover.

4 - 22

RX 50 Racing
Fill the cooling system with recommended coolant.

ENGINE

Fit the muffler to the vehicle.

Fix the two cylinder springs.

4 - 23

ENGINE
Connect the secondary air pipe and tighten the relevant clamp.

RX 50 Racing

Fit the screw securing the muffler to the frame and tighten it to the specified torque. (10 Nm)

Tighten the clamp securing the silencer to the muffler.

4 - 24

RX 50 Racing
Fit the fuel tank to the vehicle.

ENGINE

Fit the fuel pipe to the cock.

Connect the breather hose to the cap.

On both sides, fit the two fuel tank side screws and tighten them to the specified torque. (10 Nm)

4 - 25

ENGINE
Fit the centre screw securing the fuel tank to the frame and tighten it to the specified torque. (25 Nm)

RX 50 Racing

Fit the left-hand air scoop to the fuel tank and tighten the two side screws. Repeat the procedure for the right-hand air scoop.

On both sides, tighten the two screws joining the scoops to the radiator cowling.

4 - 26

RX 50 Racing

ENGINE

Fit the two elastic bands securing the air scoops.

Fit the seat.

4 - 27

ENGINE
Tighten the seat nut.

RX 50 Racing

4 - 28

RX 50 Racing
4.1.3. TIGHTENING TORQUE SETTINGS

ENGINE

COMPONENT

Torque (Nm) ENGINE Engine-to-frame fastening

Notes

Front fastener Upper and lower rear fastener Front sprocket cover Mixer cover Cable fastener on engine Starting lever Gearchange lever Engine clutch adjuster Silencer Muffler Silencer clamp Sleeve clamp, air box side Sleeve clamp, engine side

25 25 Parts fastened to the engine 3 3 7 10 15 7 EXHAUST SYSTEM 25 10 8 CARBURETTOR 3 3

4 - 29

ENGINE

RX 50 Racing

4.2.
4.2.1.

ENGINE OUTER COMPONENTS


REMOVING ENGINE OUTER COMPONENTS

1.

REMOVING THE AIR BOX (1) Remove the right-hand and left-hand side body panels, see 5.1.1 (REMOVING THE OUTER STRUCTURES). Remove the battery, see 5.7.1 (REMOVING THE ELECTRIC COMPONENTS). Remove the flasher relay, see 5.7.1 (REMOVING THE ELECTRIC COMPONENTS). Remove the fuse carrier-diode grommet. Loosen and remove the screw (4). Loosen the clamp (5) joining the air box (1) to the carburettor. Remove the air box (1).

4 - 30

RX 50 Racing
2. REMOVING THE MIXER OIL RESERVOIR / EXPANSION RESERVOIR (6) Remove the seat, see 5.1.1 (REMOVING THE OUTER STRUCTURES). Remove the right-hand and left-hand air scoops, see 5.1.1 (REMOVING THE OUTER STRUCTURES). Remove the fuel tank, see 5.1.1 (REMOVING THE OUTER STRUCTURES). Loosen and remove the two screws (7) securing mixer oil reservoir/expansion reservoir to the frame. Loosen clamp (8) and remove the pipe (9) from the radiator (12). Disconnect the connectors (11) of oil reserve indicator. Remove the mixer oil reservoir / expansion reservoir (6). REMOVING THE RADIATOR (12) Remove the seat, see 5.1.1 (REMOVING THE OUTER STRUCTURES). Remove the right-hand and left-hand air scoops, see 5.1.1 (REMOVING THE OUTER STRUCTURES). Remove the radiator cowling, see 5.1.1 (REMOVING THE OUTER STRUCTURES). Loosen the screw with copper washer from the water pump cover and drain all coolant from the cooling system. Loosen the clamps (15) and (16) and remove the pipes. Loosen the clamp (8) and remove the pipe (9) from the radiator. Loosen and remove the screw (13) and the screw (14). Slightly lift the radiator (12) and remove it. REMOVING THE SILENCER (17) Remove the right-hand side body panel, see 5.1.1 (REMOVING THE LH AND RH SIDE BODY PANELS). Loosen and remove the screw (18), make sure you follow the correct order of assembly: washers (19), cush drive rubber (20), spacer (21), nut (22). Loosen the clamp (23) securing the muffler to the silencer. Remove the silencer (17).

ENGINE

3. 4.

5.

REMOVING THE MUFFLER (24) Loosen the clamp (23) securing the muffler to the silencer. Release the two cylinder springs (25). Release the secondary air pipe clamp (38) and remove the pipe (39). Loosen and remove the screw (26). Remove the muffler (24).

4 - 31

ENGINE
6. REMOVING THE CARBURETTOR (27) Remove the fuel tank, see 5.1.1 (REMOVING THE OUTER STRUCTURES). Remove the throttle cable (28) from the carburettor (27). Remove the choke cable (40) from the carburettor (27). Remove the mixer oil pipe. Loosen the screw with copper washer from water pump cover and drain all coolant from the cooling system. Release the two clamps and remove the carburettor heating pipes (31) from carburettor (27). Loosen the clamp (5) joining the carburettor (27) to the air box (1). Loosen the clamp (37) on intake manifold and separate the carburettor (27) from the manifold. Remove the carburettor (27).

RX 50 Racing

4 - 32

RX 50 Racing
4.2.2. TIGHTENING TORQUE SETTINGS

ENGINE

COMPONENT

Torque (Nm) COOLING SYSTEM

Notes

Radiator cowling Radiator Silencer Muffler Silencer clamp Air box-to-frame Air box cover Sleeve clamp, air box side Sleeve clamp, engine side

5 5 EXHAUST SYSTEM 25 10 8 AIR BOX 3 2 CARBURETTOR 3 3

4 - 33

RX 50 Racing

CHASSIS

CHASSIS

5-1

CHASSIS

RX 50 Racing

SUMMARY
5.1. OUTER STRUCTURES.................................................................................................................................... 3 5.1.1. REMOVING THE OUTER STRUCTURES ................................................................................................ 3 5.1.2. TIGHTENING TORQUE SETTINGS ......................................................................................................... 8 5.2. FRONT FORK................................................................................................................................................... 9 5.2.1. REMOVING THE FORK LEGS.................................................................................................................. 9 5.2.2. REFITTING THE FORK LEGS ................................................................................................................ 14 5.2.3. DISASSEMBLING AND OVERHAULING THE FORK LEGS FOR CHANGING THE OIL AND THE OIL SEALS ..................................................................................................................................................... 18 5.2.4. REASSEMBLING THE FORK LEGS....................................................................................................... 23 5.2.5. TIGHTENING TORQUE SETTINGS ....................................................................................................... 30 5.3. REAR SUSPENSION - FRAME COMPONENTS ........................................................................................... 31 5.3.1. REMOVING THE REAR SUSPENSION, THE SIDE STAND AND THE FOOTPEGS............................. 31 5.3.2. TIGHTENING TORQUE SETTINGS ....................................................................................................... 33 5.4. SWINGING ARM ............................................................................................................................................ 34 5.4.1. REMOVING THE SWINGING ARM......................................................................................................... 34 5.4.2. REFITTING THE SWINGING ARM ......................................................................................................... 38 5.4.3. TIGHTENING TORQUE SETTINGS ....................................................................................................... 42 5.5. BRAKING SYSTEM WHEELS ..................................................................................................................... 43 5.5.1. REMOVING THE BRAKE SYSTEMS AND WHEELS ............................................................................. 43 5.5.2. TIGHTENING TORQUE SETTINGS ....................................................................................................... 45 5.6. CHAIN............................................................................................................................................................. 46 5.6.1. DISASSEMBLING THE DRIVE CHAIN ................................................................................................... 46 5.6.2. REASSEMBLING THE DRIVE CHAIN .................................................................................................... 48 5.7. ELECTRIC COMPONENTS............................................................................................................................ 50 5.7.1. REMOVING THE ELECTRIC COMPONENTS........................................................................................ 50 5.7.2. TIGHTENING TORQUE SETTINGS ....................................................................................................... 54

5-2

RX 50 Racing

CHASSIS

5.1.
5.1.1.

OUTER STRUCTURES
REMOVING THE OUTER STRUCTURES

1.

REMOVING THE SEAT (1) Loosen and remove the nut (2) located under the seat (1). Remove the seat.

5-3

CHASSIS
2. REMOVING THE RIGHT (4) AND LEFT (5) AIR SCOOPS Remove the two O-rings (46) on the air scoops. Loosen and remove the two screws (6) securing air scoop (4), (5), to radiator cowling (7). Loosen and remove the two screws (3) securing the air scoop (4), (5) to the fuel tank. Remove the air scoops.

RX 50 Racing

3.

REMOVING THE RADIATOR COWLING (7) Loosen and remove the screw (8) securing the radiator cowling (7) to the frame. Loosen and remove the two screws (6) securing air scoop (4), (5) to radiator cowling (7). Pull down the radiator cowling (7) and remove it, with the handlebar turned on one side.

4.

REMOVING THE LEFT (9) AND RIGHT (10) SIDE BODY PANELS Loosen and remove the screw (11) securing the side body panel (9), (10) to the frame. Remove the side body panels.

5.

REMOVING THE TOOL BAG (12) Remove the left-hand side body panel (9) following the procedure described (REMOVING THE LH AND RH SIDE BODY PANELS). Loosen and remove the two tool bag screws (12). Remove the tool bag.

5-4

RX 50 Racing
6. REMOVING THE TAIL GUARD (17) Remove the seat (1) following the procedure described (REMOVING THE SEAT). Loosen and remove the two screws (14), collect the nut (15) underneath. Loosen and remove the two screws (16) securing the tail guard (17) to the frame. Remove the tail guard.

CHASSIS

7.

REMOVING THE NUMBER PLATE HOLDER (18) Remove the seat (1) following the procedure described (REMOVING THE SEAT). Remove the tail guard (17) following the procedure described (REMOVING THE TAIL GUARD). Remove the rear direction indicators, see 5.7.1 (REMOVING THE ELECTRIC COMPONENTS). Remove the tail light connector (the connector is on the battery). Remove the number plate holder.

8.

REMOVING THE HEADLIGHT HOLDER (20) Remove the two O-rings (21). Hold the headlight holder (20) in your hands and remove the headlight connectors. Remove the headlight holder.

9.

REMOVING THE FRONT MUDGUARD (22) Loosen and remove the four screws (23) securing the mudguard to the fork bottom yoke. Remove the front mudguard (22).

5-5

CHASSIS
10. REMOVING THE RIGHT (24) AND LEFT (25) FORK LEG GUARDS Loosen and remove the three screws (26). Working on the left-hand fork leg guard (25), loosen and remove the two screws (27), collect the nuts (30) and remove the front brake line and the odometer sensor wire. Remove the fork leg guard.

RX 50 Racing

11.

REMOVING THE CHAIN GUARD (31) Loosen and remove the two screws (32). Remove the chain guard.

12.

REMOVING THE FRONT SPROCKET GUARD (33) Loosen and remove the two screws (34). Remove the front sprocket guard.

13.

REMOVING THE SHOCK ABSORBER GUARD (35) Remove the side body panels following the procedure described [REMOVING THE LH (9) AND RH (10) SIDE BODY PANELS]. Loosen and remove the two screws (36), pay attention at reassembly that the earth wire (42) is secured on the left one. Loosen and remove the screw (37).

5-6

RX 50 Racing
14. REMOVING THE FUEL TANK (38) Remove the seat following the procedure described [REMOVING THE SEAT (1)]. Remove the right-hand and left-hand air scoops following the procedure described [REMOVING THE RH (4) AND LH (5) AIR SCOOPS]. Loosen and remove the centre screw (39) securing the fuel tank (38) to the frame. Loosen and remove the two side screws (40). Disconnect the breather hose on the fuel tank cap. Close the fuel cock (41) under the fuel tank (38). Disconnect the tank/carburettor fuel pipe from the cock end. Remove the fuel tank.

CHASSIS

15.

REMOVING THE RIGHT (45) AND LEFT (44) REAR VIEW MIRRORS Loosen the lock nut. Remove the mirror.

16.

REMOVING THE HANDLEBAR (48) Remove the rear view mirrors (44), (45) following the procedure described [REMOVING THE RIGHT-HAND (45), LEFT-HAND (44) REAR VIEW MIRRORS]. Remove the front brake master cylinder, see 5.5.1 (REMOVING THE BRAKE SYSTEMS AND THE WHEELS) Remove the throttle control (47). Remove the left handgrip (48). Release the choke cable (49). Release the clutch cable from engine end. Remove the dimmer switch (50). Loosen the screw securing the clutch lever support to the handlebar. Remove the clutch/choke lever unit (51). Loosen the four screws (52) and remove the handlebar U-bolts (53) securing the fork upper plate (54). Remove the handlebar.

5-7

CHASSIS

RX 50 Racing

5.1.2.

TIGHTENING TORQUE SETTINGS

COMPONENT

Torque (Nm) FUEL TANK

Notes

Fuel tank - RH and LH side Fuel tank - rear Fuel cock Tool bag Front mudguard cat's eye Tail guard Air scoops Side panels Helmet lock Rider footpeg Instrument panel support plate Shock absorber guard Number plate holder-to-frame Seat Oil reservoir Fork leg guard Passenger footpeg support Handlebar Clutch lever Throttle control dowel Dimmer switch Throttle control

10 25 7 FRAME / OUTER STRUCTURES 5 1 5 5 5 10 12/20 10 3 5 10 3 3 25 HANDLEBAR AND CONTROLS 17 10 1 1 2

5-8

RX 50 Racing 5.2.
5.2.1.

CHASSIS

FRONT FORK
REMOVING THE FORK LEGS Place the vehicle on a safe support so that the front wheel is not touching the ground. Release the elastic bands securing the headlight holder to the fork legs. Disengage the headlight holder from the pin on instrument panel and slide it down.

Disconnect headlight connection and remove the headlight holder.

Loosen the fork top yoke screws.

Loosen the fork leg top caps.

5-9

CHASSIS
Remove the screws securing the direction indicator support to the fork legs.

RX 50 Racing

Remove the two screws of the brake line clamp from the left-hand fork leg guard.

Release the brake line from left-hand fork leg guard.

Loosen the fork leg guard lower screws.

5 - 10

RX 50 Racing
Remove both fork leg guards.

CHASSIS

Loosen the two front brake calliper screws.

Remove the two screws.

Remove the brake calliper from the disc, but leave the line connected.

5 - 11

CHASSIS
Loosen the shaft pinch bolts on fork bottom right side.

RX 50 Racing

Loosen and remove the front wheel shaft.

Remove the front wheel.

5 - 12

RX 50 Racing
Loosen the fork bottom yoke screws.

CHASSIS

Hold the direction indicators and remove both fork legs.

5 - 13

CHASSIS

RX 50 Racing

5.2.2.

REFITTING THE FORK LEGS Slide the fork legs through the bottom yoke, the direction indicators supports and the top yoke and set them in position.

Adjust sleeve height over the top yoke as recommended (10 mm) and tighten all screws on fork yokes to the specified torque. (Top 25 Nm - Bottom 10 Nm).

Fit the front wheel.

5 - 14

RX 50 Racing
Fit the wheel shaft.

CHASSIS

Screw in the wheel shaft and tighten it to the specified torque. (80 Nm)

Check that the fork moves smoothly, tighten the shaft pinch bolts on fork bottom end to the specified torque. (10 Nm)

Fit the brake calliper and odometer sensor support plate, tighten the securing screws to the specified torque (25 Nm), then operate the brake several times to set the pads back in position.

5 - 15

CHASSIS

RX 50 Racing

Fit the fork leg guards, tighten the screws to the specified torque (3 Nm).

Fit odometer sensor cable and brake line to left fork leg guard clamp.

5 - 16

RX 50 Racing
Fit the two clamp screws.

CHASSIS

Fit the direction indicators to the fork legs and tighten the support screws.

Connect the headlight connection.

Fit the headlight holder in the pin on instrument panel and secure the two elastic bands to the fork legs.

5 - 17

CHASSIS

RX 50 Racing

5.2.3.

DISASSEMBLING AND OVERHAULING THE FORK LEGS FOR CHANGING THE OIL AND THE OIL SEALS Carefully clean the fork leg and take a container with a capacity over 500 cu cm. Set the sleeve in a vice with soft jaws and tighten slightly to avoid any damage. Push the fork bottom end up, fully home on the sleeve and support it at the bottom. Use a hexagonal spanner to completely loosen the top cap. Make sure the O-ring is not damaged during removal.

Use an open-end spanner to hold the lock nut on damper rod and loosen the top cap. Loosen and remove the top cap from the damper rod.

Remove the spring.

Drain all oil from the fork leg, pay attention not to remove the sleeve from the fork leg.

5 - 18

RX 50 Racing
Pump the cartridge a few times keeping the fork leg vertical to drain all oil from the cartridge.

CHASSIS

Drain again all oil from the fork leg.

Clamp the fork leg, at the fork bottom end, in a vice with soft jaws, to avoid any damage. Loosen the screw and remove the fork leg guard guide.

Hold the sleeve and slide it out of the fork leg.

5- 19

CHASSIS
Set the sleeve in a vice with soft jaws and tighten slightly to avoid any damage. Use a flat screwdriver to remove the dust seal, be careful not to damage the sleeve edge. Never reuse the removed dust seals.

RX 50 Racing

Use a suitable screwdriver to remove the snap ring inside the sleeve.

Use a big flat screwdriver to remove the seal. WARNING In order not to damage the oil seal and the sleeve edge, be careful and lever at different points, over one third of the surface.

Remove the guide bush from inside the sleeve.

5 - 20

RX 50 Racing
Tap the sleeve on a flat wooden surface, keep the sleeve perpendicular to the wooden surface to remove sliding bushes and plastic spacer.

CHASSIS

Clamp the fork leg, at the fork bottom end, in a vice with soft jaws, to avoid any damage. Hold the damper rod, loosen and remove the bottom screw together with the gasket.

5- 21

CHASSIS
Remove the cartridge from inside the fork leg.

RX 50 Racing

CAUTION Carefully wash all components with suitable detergent.

5 - 22

RX 50 Racing
5.2.4. REASSEMBLING THE FORK LEGS Clamp the fork leg, at the fork bottom end, in a vice with soft jaws, to avoid any damage. Fit the damper cartridge in the fork leg.

CHASSIS

Fit and tighten the screw securing the cartridge to the fork bottom end to the specified torque. (50 Nm)

Fit the sliding bush, use the plastic spacer to push it inside the sleeve.

5 - 23

CHASSIS
Fit the other sliding bush, use a drift of suitable diameter to push it inside the sleeve, if needed.

RX 50 Racing

Lubricate the dust seal and the oil seal with a thin layer of hydraulic fluid. Fit the dust seal, the snap ring, the oil seal and the guide bush to the fork leg. Make sure to fit the dust and oil seals in the proper direction.

5 - 24

RX 50 Racing

CHASSIS

Fit the sleeve to the fork leg, fit the guide bush and the oil seal with a suitable tool.

5 - 25

CHASSIS

RX 50 Racing

Fit the snap ring with a suitable tool.

Fit the dust seal.

Fit the fork leg guard guide to the sleeve and tighten the fastening screw.

5 - 26

RX 50 Racing
Support the fork bottom end from below, set the sleeve in a vice with soft jaws and slightly tighten. Pour the recommended quantity of oil inside the sleeve. (400 cc)

CHASSIS

Slowly move up and down the rod inside the cartridge, so that oil can fill the whole volume. Carry on until you feel even resistance over the whole upstroke.

Tighten the lock nut fully home on the damper rod.

Remove the damper rod from the cartridge in the sleeve.

5 - 27

CHASSIS
Keep the damper rod in position and fit the spring.

RX 50 Racing

Use an open-end spanner fitted to the lock nut to hold the damper rod and the spring. Screw the spring in until it is completely inside the sleeve.

Screw the top cap fully home on damper rod.

Compress the spring and screw the lock nut fully home on the top cap.

5 - 28

RX 50 Racing
Hold the lock nut with an open-end spanner and tighten the top cap to the specified torque (30 Nm).

CHASSIS

Take the fork bottom end down and start the plug on the sleeve, make sure not do damage the O-ring.

Tighten the top cap to the specified torque. (25 Nm)

Fit fork leg guard guide and tighten the screw.

5 - 29

CHASSIS

RX 50 Racing

5.2.5.

TIGHTENING TORQUE SETTINGS

COMPONENT

Torque (Nm) FRONT FORK

Notes

Fork leg to top plate fastener Fork leg to bottom plate fastener Hub Steering tube nut Steering ring nut Fork leg guard

25 10 10 80 7* 3

NOTE: * indicates the final torque setting with ratchet spanner at 7Nm after having tightened to 20 Nm and loosened.

5 - 30

RX 50 Racing 5.3.
5.3.1.

CHASSIS

REAR SUSPENSION - FRAME COMPONENTS


REMOVING THE REAR SUSPENSION, THE SIDE STAND AND THE FOOTPEGS

17.

REMOVING THE SHOCK ABSORBER (1) Remove the fuel tank, see 5.1.1 (REMOVING THE OUTER STRUCTURES). Remove the right-hand side body panel, see 5.1.1 (REMOVING THE OUTER STRUCTURES). Securely fix the vehicle rear end so to avoid any damage or injury. Loosen and remove the screw (2) securing the shock absorber (1) to the frame (15), collect the nut (3). Loosen and remove the screw (4) securing the shock absorber (1) to the double connecting rod (7), collect the nut (5) and the roller bearing (6). WARNING Grease the reassembling. roller bearing (6) when

Remove the shock absorber (1)

5 - 31

CHASSIS
18. REMOVING THE DOUBLE connecting rod (7) AND THE SINGLE connecting rod (8) Securely fix the vehicle rear end so to avoid any damage or injury. Remove the shock absorber (1), following the procedure described [REMOVING THE SHOCK ABSORBER (1)]. Loosen and remove the centre screw (11) of the double connecting rod (7), collect the nut (9) and the roller bearing (10). WARNING Grease the reassembling. roller bearing (10) when

RX 50 Racing

Loosen and remove the screw (13) securing the single connecting rod (8) to the frame (15), collect the nut (12) and the spacer (14). WARNING Grease the spacer (14) when reassembling. Remove the double connecting rod (7) and single connecting rod (8) assembly. REMOVING THE SIDE STAND (16) Remove the spring unit (17). Loosen and remove the nut (18), collect the bolt (19). WARNING When assembling, grease and apply Loctite 243 before tightening the nut and the bolt. Remove the side stand (16).

19.

20.

REMOVING THE RIGHT (20) AND LEFT (21) RIDER FOOTPEGS Loosen and remove the screw (22), collect the nut (23) and the spring (24). Remove the rider footpeg (20) or (21). Repeat the above procedure for the other footpeg.

5 - 32

RX 50 Racing
5.3.2. TIGHTENING TORQUE SETTINGS

CHASSIS

COMPONENT

Torque (Nm) REAR SUSPENSION Shock absorber

Notes

Shock absorber Double connecting rod Single connecting rod Rider footpeg Side stand screw Side stand nut

50 Connecting rods 50 50 FRAME / OUTER STRUCTURES 12/20 SIDE STAND 10 35

Lubricate and apply Loctite 243 Lubricate and apply Loctite 243

5 - 33

CHASSIS

RX 50 Racing

5.4.
5.4.1.

SWINGING ARM
REMOVING THE SWINGING ARM Place the vehicle on a safe support so that the rear wheel is not touching the ground.

Loosen and remove the wheel shaft nut.

Remove the flat washer beneath.

Remove the left chain tensioner.

5 - 34

RX 50 Racing
Manually push the wheel shaft in the hub and collect the spacer.

CHASSIS

Remove the chain from the rear sprocket and move it aside.

Remove the wheel shaft and the wheel, collect the spacer on brake calliper side.

Disconnect the rear brake line from the two cable guides and move the brake calliper to the right outer side.

5 - 35

CHASSIS

RX 50 Racing

Loosen the two screws and remove the chain guard.

Remove the screw securing the double connecting rod to the swinging arm.

5 - 36

RX 50 Racing
Remove the screw securing the single connecting rod to the frame.

CHASSIS

Remove the pin securing the swinging arm to the frame.

Remove the swinging arm from the frame.

5 - 37

CHASSIS

RX 50 Racing

5.4.2.

REFITTING THE SWINGING ARM

CAUTION Before refitting, grease the double connecting rod roller bearing, the single connecting rod inner spacer and the two swinging arm articulating bushes with lithium grease. Fit the swinging arm to the frame.

CAUTION Make sure to correctly refit the chain and the rear brake calliper.

Fit the swinging arm shaft and tighten it to the specified torque (100 Nm).

Fit the screw securing the single connecting rod to the frame and tighten it to the specified torque (50 Nm).

Fit the screw securing the double connecting rod to the swinging arm and tighten it to the specified torque (50 Nm).

5 - 38

RX 50 Racing
Fit the chain guard, route the chain through the guard.

CHASSIS

Fit the rear brake line in the two open cable guides and fit the rear calliper plate to the swinging arm.

Close the two cable guides.

5 - 39

CHASSIS
Fit the rear wheel and the spacer on brake calliper side, partially insert the wheel shaft.

RX 50 Racing

Wrap the chain around the rear sprocket.

Fit the inner spacer and the wheel shaft fully home.

Fit the chain tensioner, the flat washer and the wheel shaft nut.

5 - 40

RX 50 Racing

CHASSIS

Tighten the wheel shaft to the specified torque (100 Nm).

5 - 41

CHASSIS

RX 50 Racing

5.4.3.

TIGHTENING TORQUE SETTINGS

COMPONENT

Torque (Nm) SWINGING ARM

Notes

Swinging arm shaft Chain guard Rear chain guide Chain sliding shoe

100 6 10 25 REAR SUSPENSION Shock absorber

Lubricate -

Shock absorber Single connecting rod Double connecting rod

50 Connecting rods 50 50

5- 42

RX 50 Racing 5.5.
5.5.1.

CHASSIS

BRAKING SYSTEM WHEELS


REMOVING THE BRAKE SYSTEMS AND WHEELS

1.

REMOVING THE FRONT BRAKE SYSTEM (1) Detach the front brake line (2) from upper cable guide (3) in the direction indicator support. Detach the front brake line (2) from cable guide secured to left fork leg guard, remove the left fork leg guard, see 5.1.1 (REMOVING THE OUTER STRUCTURES). Cut the plastic ties to release odometer sensor cable from the brake line (2). Loosen the two calliper screws (4) and remove the front brake calliper (5). Disconnect front brake switch wiring. Loosen the two screws (6) and remove the U-bolt (7) securing the brake master cylinder (8). Remove the front brake system (1).

CAUTION: Always keep the reservoir above the brake calliper.

5 - 43

CHASSIS
2. REMOVING THE REAR BRAKE SYSTEM (9) Remove the right-hand side body panel, see 5.1.1 (REMOVING THE OUTER STRUCTURES). Remove the clip (10) connecting the rear brake master cylinder (11) to the rear brake lever (12). Disconnect the brake switch wiring. Open the swinging arm cable guides and detach the rear brake lines from the swinging arm. Loosen the two calliper screws (13) and remove the rear brake calliper (14). Loosen and remove the screw (15) securing the oil reservoir (16). Loosen the rear brake master cylinder (11) screws (17). Remove the rear brake system (9).

RX 50 Racing

CAUTION: Always keep the reservoir above the brake calliper. CAUTION: Carefully route the rear brake line on the frame, set it at a suitable distance from the exhaust system. 3. REMOVING THE FRONT WHEEL (18) Loosen the two front wheel shaft pinch bolts positioned on right fork leg bottom end. Loosen and remove the front wheel shaft (19), make sure to follow this sequence: spacer (23). WARNING Grease when reassembling. Remove the front wheel (18).

4.

REMOVING THE REAR WHEEL (24) Loosen and remove the rear wheel shaft (25), make sure to follow this sequence: self-locking nut (26), flat washers (27), chain tensioners (28), spacer (36), spacer (29), brake calliper plate (30), spacer (31). WARNING Grease when reassembling.

Remove the chain (34) from the rear sprocket (35). WARNING Grease when reassembling.

Remove the rear wheel (24).

5.

REMOVING THE MAGNET ASSEMBLY (38) Remove the circlip (37) securing the magnet assembly (38). Remove the magnet assembly (38) from the front brake disc.

CAUTION: When reassembling, apply Loctite 243 and set circlip hooks toward the wheel centre.

5 - 44

RX 50 Racing
5.5.2. TIGHTENING TORQUE SETTINGS

CHASSIS

COMPONENT

Torque (Nm) FRONT WHEEL

Notes

Wheel shaft nut Wheel shaft nut

80 REAR WHEEL 100 BRAKING SYSTEMS Front system

Lubricate Lubricate

Front brake calliper Front brake line guide Rear brake calliper Rear brake lever Rear brake master cylinder Rear brake master cylinder guard Rear brake fluid reservoir

25 2 Rear system 25 25 10 10 3

5 - 45

CHASSIS

RX 50 Racing

5.6.
5.6.1.

CHAIN
DISASSEMBLING THE DRIVE CHAIN

TOOL TO BREAK / JOIN THE CHAIN CAUTION: Take the suitable special tool (part no. 8140192) aprilia part# 8140192 (Tool to remove / reassemble the chain).

CAUTION: This tool is used for breaking/joining chains with rivet links. WARNING Use only chains with rivet links on this vehicle.

5 - 46

RX 50 Racing
Key 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Main body Fixed hexagonal flat (for 27mm spanner) Hexagonal-head screw (for 19mm spanner) Centring pin Riveting tool Reference marks A and B Reference holes for jointing pins Pin hole Pusher Breaking side Jointing side Support plate Jointing plate Riveting plate

CHASSIS

BREAKING THE CHAIN Remove the front sprocket cover, see 5.1.1 (REMOVING THE OUTER STRUCTURES). Slacken the chain. Place the vehicle on the suitable rear paddock stand. CAUTION Make sure that the tool used is suitable for the chain fitted to the vehicle and for the size of the links.

Set the riveting tool (1) on the lower section of the chain, between front and rear sprocket. Move the riveting tool (1) along the chain so to match the pin centre hole on the tool with the pin to be removed. Fit the pusher (2), with the larger side facing the main body (3). Fit the main body (3) on the riveting tool (1). Move the main body (3) so to match centring pin (4) with the marking A on the riveting tool (1). Snug the screw (5) finger tight until the pusher (2) contacts the pin to be removed.

CAUTION Make sure that the pusher (2) is perfectly aligned with the pin to be removed.

Fit a 27mm spanner to the fixed hexagonal flat on the centre body (3) to hold it. With a 19mm spanner, tighten the screw (5) until the chain pin is completely out. Loosen the screw (5). Repeat the same procedure on the other pin of the same link. Remove the parts of the broken link. Remove the chain. WARNING If the chain is badly worn, replace the whole unit (chain, front and rear sprockets).

5 - 47

CHASSIS

RX 50 Racing

5.6.2.

REASSEMBLING THE DRIVE CHAIN

POSITIONING THE MASTER LINK WARNING Make sure that the master link being used is the same type as the chain. Position the chain on the vehicle with the two ends to be joined set in the lower section, between front and rear sprocket. Grease the two pins on the jointing plate, see 2.1.3 (LUBRICANT TABLE). Join the two chain ends and fit the jointing plate pins. Fit the riveting plate on the pins. Position the support plate (6) on the riveting plate. Set the riveting tool (1) on the chain. Move the riveting tool (1) so to match the side holes on the tool with the pin heads on jointing plate. Fit the pusher (2), with the smaller side facing the main body (3). Fit the main body (3) on the riveting tool (1). Move the main body (3) so to match centring pin (4) with the mark A. Start the screw (5) in its thread finger tight until the pusher (2) contacts the support plate (6). Fit a 27mm spanner to the fixed hexagonal flat on the main body (3) to hold it. With a 19mm spanner, tighten the screw (5) fully home.

RIVETING THE PINS With the tool already set on the chain: Align the screw (5). Remove the main body (3) from the riveting tool (1). Remove the support plate (6). Refit the main body (3) on the riveting tool (1). Move the main body (3) so to match centring pin (4) with the marking B on the riveting tool (1). Start the screw (5) in its thread finger tight until the pusher (2) contacts the pin to be riveted.

CAUTION: Make sure that the pusher (2) is perfectly aligned with the pin to be riveted.

5 - 48

RX 50 Racing
WARNING Wear safety goggles or an eye protector. Fit a 27mm spanner to the fixed hexagonal flat on the main body (3) to hold it. With a 19mm spanner, tighten the screw (5) until the pin is riveted. WARNING Make sure that the pin is riveted correctly; the riveted pin edge should evenly contact the riveting plate and its maximum diameter should be 5.65 0.15 mm. Loosen the screw (5).

CHASSIS

Repeat the same procedure on the other pin of the same link.

5 - 49

CHASSIS

RX 50 Racing

5.7.
5.7.1.

ELECTRIC COMPONENTS
REMOVING THE ELECTRIC COMPONENTS

1.

REMOVING THE RIGHT (1) AND LEFT (2) REAR DIRECTION INDICATORS Loosen and remove the screw (3), collect the nut (4). Disconnect the connector (5). If necessary, repeat the procedure for the other direction indicator.

CAUTION To remove the direction indicator glass only, loosen and remove the retaining screw. If necessary, remove the direction indicator glass and change the bulb.

2.

REMOVING THE TAIL LIGHT (10) Loosen and remove the two screws (9) and remove the tail light glass (11). Disconnect the three connections (8) from tail light body end (6). Remove the tail light body (6).

5 - 50

RX 50 Racing
3. REMOVING THE HEADLIGHT (12) Remove the headlight holder, see 5.1.1 (REMOVING THE OUTER STRUCTURES). Loosen and remove the two screws (13). Loosen and remove the screw (14) (beam setting screw). Disconnect the connectors (15) Remove the headlight (12).

CHASSIS

4.

REMOVING THE RIGHT (16) AND LEFT (17) FRONT DIRECTION INDICATORS Loosen and remove the screw (18). Remove the headlight holder and disconnect the connector (19) or (20), see 5.1.1 (REMOVING THE OUTER STRUCTURES).

CAUTION To remove the direction indicator glass only, loosen and remove the retaining screw. If necessary, remove the direction indicator glass and change the bulb.

5.

REMOVING THE INSTRUMENT PANEL (21) Remove the headlight holder, see 5.1.1 (REMOVING THE OUTER STRUCTURES). Disconnect instrument panel lights connector. Remove the light holder from the instrument panel box. Disconnect the odometer sensor cable connector. Loosen and remove the two screws (29) securing the instrument panel to the support plate (27). Remove the instrument panel box (23) and the multifunction instrument (24).

5 - 51

CHASSIS

RX 50 Racing

6.

REMOVING THE BATTERY (33) Remove the left-hand side body panel, see 5.1.1 (REMOVING THE OUTER STRUCTURES). Loosen and remove the four screws and remove the battery cover. WARNING One of the four screws is fitted with a rubber washer; be careful when assembling it.

Turn the battery (33) clockwise and pull it down to remove it. Disconnect the negative wire (-) first, then the positive one (+) from the battery (33). WARNING Reconnect the positive cable (+) first and then the negative one (-).

7.

REMOVING THE FLASHER RELAY (34) Remove the seat and the right-hand side body panel, see 5.1.1 (REMOVING THE OUTER STRUCTURES). Remove the flasher relay (34).

8.

REMOVING THE FUSE (32) AND THE FUSE CARRIER-DIODE GROMMET (35) Remove the seat and the right-hand side body panel, see 5.1.1 (REMOVING THE OUTER STRUCTURES). Remove the fuse (32) and/or the fuse carrier-diode grommet (35).

5 - 52

RX 50 Racing
9. REMOVING THE TRANSDUCER (36) AND THE VOLTAGE REGULATOR (37) Remove the fuel tank, see 5.1.1 (REMOVING THE OUTER STRUCTURES). Loosen and remove the two screws (38), collect the nut (39). Properly mark the wiring before disconnecting it. Remove the coil (36). Loosen and remove the bolt (40), collect the nut (41). Properly mark the wiring before disconnecting it. Remove the voltage regulator (37).

CHASSIS

10.

REMOVING THE HORN (42) Remove the fuel tank, see 5.1.1 (REMOVING THE OUTER STRUCTURES). Disconnect the connectors (44). Loosen and remove the expansion reservoir lower screw. Remove the horn (42).

5 - 53

CHASSIS

RX 50 Racing

5.7.2.

TIGHTENING TORQUE SETTINGS

COMPONENT

Torque (Nm) ELECTRIC SYSTEM

Notes

Battery negative cable Key ignition switch Headlight Tail light Front direction indicators bulb Coil

3 25 1 1 2 10

5 - 54

RX 50 Racing

ELECTRIC SYSTEM

ELECTRIC SYSTEM

6-1

ELECTRIC SYSTEM

RX 50 Racing

SUMMARY
6.1. ELECTRIC SYSTEM ....................................................................................................................................... 3 6.1.1. WIRING DIAGRAM ................................................................................................................................ 3

6-2

RX 50 Racing 6.1.
6.1.1.

ELECTRIC SYSTEM

ELECTRIC SYSTEM
WIRING DIAGRAM

6-3

ELECTRIC SYSTEM
Key: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. Generator Electronic transducer Spark plug Voltage regulator Fuses Battery Front brake switch Rear brake switch Oil level sensor Neutral sensor Rear left direction indicator Tail light Rear right direction indicator Flasher Key ignition switch Two-beam headlight (low/high beam) Left dimmer switch Complete instrument panel Instrument panel bulb Direction indicators light High beam light Oil level light Neutral light Horn Front right direction indicator Low beam Front parking light Front left direction indicator Multiple connectors CABLE COLOURS Ar orange Az light blue B blue Bi white G yellow Gr grey M brown N black R red V green Vi violet

RX 50 Racing

6-4

aprilia s.p.a. via G.Galilei, 1 30033 Noale (VE) Italy tel. +39 041.5829111 fax +39 041.5829190 www.aprilia.com www.serviceaprilia.com