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View Full Version : 1999 rs50 build project



littlefeller
06-16-2011, 01:38 AM
well here it is, brought yestarday for 150 on the bay of e.
looks like a long project.
i managed to fit it all in a mondeo boot with the back seats down. looks as though it has been apart for some time but it apears to all be there apart from the piston, which looks as though it disitagrated going by the bore. however it is a cheapo ebay barrel made of iron so i could just buy a bigbore piston and bore the barrel to suit.
all the plastics need painting (any suggestions for a coulour scheam?) someone has thoughtfully rubbed it all down though.
as far as i can tell it only appears to need seats and a screen, and maybe a few nuts and bolts for the engine, which i shall try and rebuild today minus the topend.
http://img834.imageshack.us/img834/1919/dscf0082g.jpg
By littlefeller2010 (http://profile.imageshack.us/user/littlefeller2010) at 2011-06-15
http://img30.imageshack.us/img30/1958/dscf0081qk.jpg
By littlefeller2010 (http://profile.imageshack.us/user/littlefeller2010) at 2011-06-15
http://img810.imageshack.us/img810/6673/dscf0080s.jpg
By littlefeller2010 (http://profile.imageshack.us/user/littlefeller2010) at 2011-06-15
http://img807.imageshack.us/img807/3651/dscf0079x.jpg
By littlefeller2010 (http://profile.imageshack.us/user/littlefeller2010) at 2011-06-15
http://img809.imageshack.us/img809/3060/dscf0078kw.jpg
By littlefeller2010 (http://profile.imageshack.us/user/littlefeller2010) at 2011-06-15

Owen.G
06-16-2011, 04:26 PM
Are you sure thats a 1999, To me that looks like an older model. From 95 - 98 i would say. The newer model had a double swingarm, and 5 spoke wheels. That has a single swingarm and 3 spoke wheels.

Years of all the models.
http://www.apriliaforum.com/forums/showthread.php?t=83796

littlefeller
06-16-2011, 05:03 PM
wouldnt know. only got the new keeper slip so i cant check yet, but its on an s reg, unless its nicked. i know how that feels as i had a 350lc nicked just after i rebuilt it and it wasnt insured, though that was 20 years ago. so far engine bottom end is back together although it was missing the steel bearing for the gear selector drum, but a quick visit to a halfords mot centre sorted that for free. then i noticed the cluch basket retaining nut was missing, took awhile to figure which shim went where, now cant do anything else to the motor till i find a nut. although i did buy a reed valve on ebay for 4.99 used, as mine is missing. need to find a full bolt kit for the fairing now then get on with the paint jod ( anyone any ideas yet, i was thinking yellow and black) also need a top end, found that something had found its way into the cylinder and slightly squashed the piston crown, which intern had pinched the top ring and smeared the piston slightly. but i have found it has a steel bore so could just take it out to 70cc.

RS_Patrick
06-16-2011, 05:44 PM
Yep, thats not a 1999 bike...

It looks like a 1998 bike, judging by the silver pannels in the first pic and the red sidefairing.

http://www.apriliaforum.com/forums/showthread.php?t=83796

Owen.G
06-16-2011, 05:58 PM
Shes a 98 model. If you look at the side fairing sitting beside the bike is red with a white aprilia decal and you can see the tank in the pic of the fairings and its blue and the rear side ones are silver so she only matches up with the 98 model :)

RS_Patrick
06-17-2011, 05:58 AM
I dont see a Blue tank cover, just a silver one in the first picture under the rear fairings (atleast it looks like it)

But most likely its a 98, could be earlier if they swapped parts.

littlefeller
06-17-2011, 08:03 AM
no the petrol tank is primer white same as the side panels, the fairing looks as though it was red but the nose fairing was blue and silver. think its a collection of body parts from diferent years maybe. the id sticker under the seat is damaged and dificult to read but it looks like it may have been for the french market, the part of the sticker where uk should be is unreadable but there is a mark on the french part, although this might be just damage to the sticker. some of the date codes on the plastics dont match. im scratching my head trying to figure out how the oil bottle goes back on, it doesnt seem to fit anywhere.

littlefeller
06-17-2011, 08:16 AM
think it was prob blue and silver originaly but think the fairing got trashed and a red one was brought, thats prob why it was rubbed down, the nose fairing had some damage which has been repaired, to be fair they have made good the damaged nose. the only part not rubbed is the front mudguard which is electric blue - almost purple.

RS_Patrick
06-17-2011, 06:38 PM
I am not sure where the Oiltank fits but i think i recall its behind the rear side pannel bolted on the frame, but i could be confused here with an other bike.

littlefeller
06-18-2011, 03:45 AM
ok managed to find my bike on the dvla data base, bike registerd jan 1999, so it must have been the last of the 98s off the production line then registerd late. patrick rs had a look at the frame number and it was manufactured in 1998. thanx patrick

quick update, brought a reed block off ebay which arrived this morning but on opening found they have sent me the rubber manifold off a later rs, damn. in his defence though, he did message me yestarday to say he may have sent the wrong part.

also in the post there is a piston (first oversize) and a small end bearing.

still cant deside on colour though. contenders so far are yellow and black or lime green and black.
supose i should have sprayed the frame black first but cant be botherd now.
im also going to make some large lionhead decals for the faring from vinyl

littlefeller
06-18-2011, 06:31 AM
ok another small problem, are all cylinder heads for the rs the same? reason i ask is the cylinder that came with the bike has a groove cut in for the rubber gasket and the cylinder head is plain apart from the outer gasket locating groove, this barrel needs a rebore and is going to be my experimental cylinder, i borrowed a second cylinder from a friend with a good bore, problem is theres no groove for the rubber gasket, so question is does some of the cylinder heads have the locating groove instead of the cylinder? or is this cylinder simply off a later rs with the seperate head and water jacket?

littlefeller
06-18-2011, 07:30 AM
ok i can answer my own question now as i just had a look on ebay, yes there different, but i have noticed when the head is placed ontop of the cylinder with all the gaskets removed the bore touches the head first so i could just lap them together with grinding paste and do away with the gasket altogether, this is how we used to do it with racing yahaha engines.

RS_Patrick
06-18-2011, 03:57 PM
I would use gaskets mate, even if that means cutting your own, but yeah some years got difrent heads and cilinders as you noticed.

littlefeller
06-19-2011, 04:37 AM
well, result. went round to my friends house who gave me the cylinder and guess what, yep he also had the head. so now can use the proper gaskets. so now i have the spare cylinder and head that i wanted for project blow-up or project stupid power which is in the rs tech section titled big bore

supose i should rename this thread as 98 and not 99

littlefeller
06-22-2011, 02:44 PM
crist those cylinder head bolts take some finding, now sorted - ebay about 3

RS_Patrick
06-22-2011, 06:17 PM
Here you should be able top find anything you need:
www.50cc.eu
www.motorkit.com
www.easyparts.nl
www.euroscooters.nl
www.opvoeren.nl
www.scootparts.nl

littlefeller
06-24-2011, 01:14 AM
well the engine is now complete, will be starting the spray job over the weekend, but first i may put the engine back in and try and get it running just to check its ok. if anything spectcular happens i will post a video lol

littlefeller
06-25-2011, 06:16 AM
well engine now in and running, it just wanted to rev without the choke, but choke on and runs fine. checked main jet - only 63 wow. this maybe why it was in bits, prob been derestricted but left to run on the original main jet, unless the carb is from another bike.

RS_Patrick
06-25-2011, 12:32 PM
What carb is on there? should be a DelLorto SHA 12/14 if its the original one.

littlefeller
06-25-2011, 01:00 PM
yes right number, although there is a letter m after the numbers. its running very lean, no choke the revs just slowly rise untill it peaks at around 8000 then dies, choke on its fine, will go larger main jet to check for any air leaks. cant really see how it could have run like that before i brought it.
starting the spray job tomorrow, the yellow perill.

RS_Patrick
06-25-2011, 06:20 PM
If i where you i get a difrent type of carb and manifold, a RS50 Carb kit that comes with an Addaptor for the Stock Airbox and a Lever Choke or Cable Choke.
Some come with a Manifold and even reeds or a reedcage.

littlefeller
06-26-2011, 03:01 PM
yellow peril update
http://img560.imageshack.us/img560/1585/dscf0001f.jpg
By littlefeller2010 (http://profile.imageshack.us/user/littlefeller2010) at 2011-06-26
http://img28.imageshack.us/img28/8605/dscf0003t.jpg
By littlefeller2010 (http://profile.imageshack.us/user/littlefeller2010) at 2011-06-26
http://img263.imageshack.us/img263/4286/dscf0005j.jpg
By littlefeller2010 (http://profile.imageshack.us/user/littlefeller2010) at 2011-06-26
http://img402.imageshack.us/img402/3094/dscf0006ug.jpg
By littlefeller2010 (http://profile.imageshack.us/user/littlefeller2010) at 2011-06-26
http://img14.imageshack.us/img14/1888/dscf0002lq.jpg
By littlefeller2010 (http://profile.imageshack.us/user/littlefeller2010) at 2011-06-26
its looking very kenny roberts.

RS_Patrick
06-26-2011, 06:10 PM
get some race mesh to fit in the airintakes etc. i think flat black or red would look really nice with that yellow: http://www.easyparts.nl/showarticles/0-4-483-3358/Grille_Decoration.html
http://www.easyparts.nl/showarticles/0-4-483-3357/Grille_Decoration_OpticParts_]_DF.html
http://www.easyparts.nl/showarticles/0-4-483-3356/Grille_Decoration_TNT.html

littlefeller
06-28-2011, 02:27 PM
managed to fix the revs, jet arrived, installed - yes its a leak. found leak, how daft am i, im running the bike on a premix for awhile after the rebuild so carb is sucking air through the oil pump which is connected to the carb via a small rubber tube, once blocked all is fine.
yes mesh is waiting to go in, i cheated and used desposable bbq mesh, primed and painted. it has a larger mesh which looks good.
ordering decals from awsome graphics, good price too. think i will keep the decals to a minimum.

RS_Patrick
06-28-2011, 07:03 PM
If you disconect the oilpump you better remove it completly or its gonna get damadged (and cause unneeded resistance) as its not getting lubricated.

Like i said before, i keep the Oilpump, its a lot better to have the oilpump and just premix 1:100 extra trough the feultank, gives you better performance because your sparkplug doesnt foul/coke up wen you let go of the throttle and try to accelerate again.

littlefeller
06-29-2011, 11:32 AM
the pump will be used for its intended purpose once the engine has used a tankfull of enriched premix. i will take the opportunity to measure the oil that comes out. just noticed though i am missing the clutch retainer bridge, but there only around 4, will also need some exhaust springs think there 87p from aprilia, the ones i have are not the original springs.

RS_Patrick
06-29-2011, 07:11 PM
There is not much point in measuring how much oil comes out as thats controled by the throttle position and rpm, so its variable, wen the bike runs idle it puts out something like 1:100, and wen your screaming down a straight it puts out 1:33, so its oil output does not match how much feul is used.
So you cant say i used up 5 liters of feul and the oilpump put out 100ml of oil in that same time so its running 1:50, it does not work that way, you would have to lock the oilpump in the fully open position, start the bike, rev it to 6000rpm, and than keep it at 6000rpm and put the injectortube into the mesuring cup and see how much it pumps out in 1 minute.

Even than theres the problem that wen the tube is hooked up to the carb/manifold the oil not only gets pumped out, but it also gets greatly helped by the vacume effect of the engine.

RonneBear
06-30-2011, 06:08 AM
Hey,

That paint looks nice, good job.


Ronne

littlefeller
06-30-2011, 01:27 PM
thanx, its just rattle cans. there is a knack though, lots of thin coats. the prepped surface is critical. the colour is fiat broom yellow, its very close to yamaha kenny robers yellow. i couldnt deside between this yellow or lime green, so my misses desided for me.

littlefeller
07-02-2011, 10:44 AM
latest progress
http://img835.imageshack.us/img835/16/img00235o.jpg
By littlefeller2010 (http://profile.imageshack.us/user/littlefeller2010) at 2011-07-02
http://img98.imageshack.us/img98/9422/img00238y.jpg
By littlefeller2010 (http://profile.imageshack.us/user/littlefeller2010) at 2011-07-02

larger mesh looks good too
http://img11.imageshack.us/img11/4357/img00240s.jpg
By littlefeller2010 (http://profile.imageshack.us/user/littlefeller2010) at 2011-07-02
http://img841.imageshack.us/img841/2377/img00239b.jpg
By littlefeller2010 (http://profile.imageshack.us/user/littlefeller2010) at 2011-07-02

still got alot of small jobs to do, is there suposed to be a micro switch for the front break rather than a hydrolic one?

http://img685.imageshack.us/img685/913/img00032qq.jpg
By littlefeller2010 (http://profile.imageshack.us/user/littlefeller2010) at 2011-04-22
a random pic of my car too

littlefeller
07-02-2011, 02:03 PM
now making the seats, the ones on the bike are borrowed, but i can copy them
http://img231.imageshack.us/img231/8956/img00242e.jpg
By littlefeller2010 (http://profile.imageshack.us/user/littlefeller2010) at 2011-07-02
http://img42.imageshack.us/img42/8177/img00241j.jpg
By littlefeller2010 (http://profile.imageshack.us/user/littlefeller2010) at 2011-07-02
http://img706.imageshack.us/img706/5966/img00243f.jpg
By littlefeller2010 (http://profile.imageshack.us/user/littlefeller2010) at 2011-07-02
http://img684.imageshack.us/img684/8937/img00244v.jpg
By littlefeller2010 (http://profile.imageshack.us/user/littlefeller2010) at 2011-07-02
http://img98.imageshack.us/img98/1453/img00245d.jpg
By littlefeller2010 (http://profile.imageshack.us/user/littlefeller2010) at 2011-07-02
now i just need some pvc, seen some real nice leather look in the local indian, think i will go for a balti tomorow eve and take my stanley with me he he.

RS_Patrick
07-02-2011, 05:09 PM
Thers a small switch on the underside of the front brake lever/pump unit that the lever presses against, and wen you pull the brake lever it comes out and conects (reversed switch)

littlefeller
07-03-2011, 12:28 AM
yes i found the switch, i have now checked on the exploded diagrams at aprilia and the switch is std fitment, however the friend who i borrowed the seats from has a diferent setup, his uses the same switch as the one for the rear brake. at first i though it wasnt right but then noticed it also had a rubber cover which was made for it. the bike is a q plate which in the uk is used for kitcars or some imports that are not registerd, could this be an old race bike?. were some 98 models fitted with this kind of switch?.

RS_Patrick
07-03-2011, 06:01 AM
No, he must have a difrent front brakepump.

littlefeller
07-03-2011, 06:38 AM
i dont think so, but i supose its just held there with the threaded end instead of a banjo bolt. maybe retro fit, the pump is the same as mine, but the rubber cover uuummm

RS_Patrick
07-03-2011, 05:37 PM
Its posible they fitted one instead of the Banjobolt but i prefer the normal electronic switch, easier to troubleshoot, and if it breaks it easy and cheap to replace.

littlefeller
07-06-2011, 01:21 AM
yes, im considering replacing my rear for an electrical switch too, my friend borrowed my rear switch for his mot has his has failed, when fitted mine didnt work on his bike either, but if you jump the terminals light comes on as it should, unless his rear cylinder isnt functioning as it should. never actually tested it on my bike yet.

littlefeller
07-10-2011, 06:41 AM
latest progress, seats have come out ok
http://img225.imageshack.us/img225/8739/dscf0009yv.jpg
By littlefeller2010 (http://profile.imageshack.us/user/littlefeller2010) at 2011-07-10
http://img546.imageshack.us/img546/7720/dscf0008a.jpg
By littlefeller2010 (http://profile.imageshack.us/user/littlefeller2010) at 2011-07-10

just awaiting delivery of a screen now, cant find one off an rs50 but managed to find one for an rs250, hoping i can make it fit

littlefeller
07-10-2011, 06:47 AM
yes, im considering replacing my rear for an electrical switch too, my friend borrowed my rear switch for his mot has his has failed, when fitted mine didnt work on his bike either, but if you jump the terminals light comes on as it should, unless his rear cylinder isnt functioning as it should. never actually tested it on my bike yet.

now fitted the rear switch, and its working. just got back from friends house who has the dodgy switches, had a look at them and some numpty has wired the front switch directly to the rear switch.

littlefeller
07-10-2011, 07:38 AM
does anyone happen to know if the 250 screen would fit, if you buy aftermarket screens, they are listed as the same?

littlefeller
07-10-2011, 04:31 PM
for some odd reason this forum isnt marking these posts as new.
oh its ok - working now

Owen.G
07-11-2011, 07:13 AM
i like this bike alot now . Grteat job lad, Such a differnce, i cant even believe its the same bike :)

RS_Patrick
07-11-2011, 11:49 AM
for some odd reason this forum isnt marking these posts as new.
oh its ok - working now

Probably your Browser settings, doesnt refresh automaticly.

littlefeller
07-11-2011, 11:58 AM
thanks, i have had a few kind messages of encouragement. thinking about doind another now, total spend so far
150 - bike
18 - new piston
4 - small end bearing
1.99 - bulb
68 - paint
60p - 3 engine bolts
75p - 7mm nuts for cylinder head
and just spent 12 on a screen
all in all around 250. not bad
wonder if theres any money in this?

RS_Patrick
07-11-2011, 06:04 PM
Probably not because your probably lucky that this bike has no mechanical flaws like for example in the engine or gearbox (atleast i hope it does not)

littlefeller
07-12-2011, 11:06 AM
mechanical flaws are not a problem as i have a well equiped workshop, will also be piling up the spares, theres loads about, usually knackerd engine.
so i think i will be bizzy. maybe one off paint jobs too

littlefeller
08-13-2011, 05:48 AM
FINNISHED
finaly got the time to complete this.
unfortunatly new job had put the brakes on for me.
http://img689.imageshack.us/img689/4488/img00266.jpg
By littlefeller2010 (http://profile.imageshack.us/user/littlefeller2010) at 2011-08-13

http://img24.imageshack.us/img24/7509/dscf0012mo.jpg
By littlefeller2010 (http://profile.imageshack.us/user/littlefeller2010) at 2011-08-13

http://img641.imageshack.us/img641/9540/dscf0014i.jpg
By littlefeller2010 (http://profile.imageshack.us/user/littlefeller2010) at 2011-08-13

:devil:

RS_Patrick
08-13-2011, 09:10 AM
Looks nice, could do with some red or black striping,bits though...

littlefeller
08-13-2011, 02:13 PM
kept it simple, the original thought was kenny roberts yellow and black, but never got around to it.
has anyone done an engine transplant in the earlyer tube frame with the single sided swingarm?

still cant find the damn seats, unless i buy new

RS_Patrick
08-13-2011, 06:15 PM
engine transplant for what?

Steve / AF1 Racing
08-13-2011, 09:56 PM
Ace job, man, really looks good. Glad you took the time to do it right. I really like seeing the older Aprilias kept up and in good condition.

littlefeller
08-13-2011, 11:42 PM
after seeing the yz build, was thinking tzr. the problem is the tube frame doesnt have a removable engine cradle and i may have problems just getting a larger engine in there, unless i build it in situ, seen loads of threads with the later frame but not the earlyer one.

RS_Patrick
08-14-2011, 05:59 AM
You can fit a bigger engine in there but i would just sell it as it is mate, maybe add some red striping etc to the paintjob to make it look better, and sell it.

You would have to reweld the frame, and than you got the problem of finding sprockets as the rear sprockets for this bike are only 3/16 whide, not 1/4 like on a the newer types.

Burns
08-19-2011, 08:18 PM
Looks really nice. from looking at the first few pictures it looks like mine :D

http://i25.photobucket.com/albums/c90/mikecom/Photo0029.jpg

1998 Rossi Rep :)

littlefeller
08-20-2011, 04:46 AM
thanks, yes its a 98, not 99 as the thread sugests. it was advertised as a 99 simply because it was declared new in jan 99 but it is infact a 98 model the same as yours.
think i prefer the earlyer ones. im not to keen on the cast ally frames, always thought they would crack where as ours would just flex.

just had a look at the earlyer pics where it is still in bits, yes the colour scheme looks identicle, some of the pannels where primed, but the underside of these parts mach your colour scheme.
i was thinking it was just a collection of parts from different bikes but now i know otherwise , good spot thanks.

littlefeller
08-20-2011, 05:10 AM
the pics with the engine in pieces looks the same now as i have another engine taking up the space now

RS_Patrick
08-20-2011, 09:45 AM
Actualy the Aluminium frame is a lot stonger and provides better handling caracteristics.

JimmySR
08-20-2011, 12:04 PM
very nice looks like you done a good job :)

Burns
08-20-2011, 04:06 PM
i have to agree with you that the older model is much nicer, i have the 98 and the 2001 model. im not a fan of the frame and rear seat but the riding position is much nicer and feels stronger and snug.