Aprilia RS250 1997 Repair Service Manual

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📚 Vehicle Manual Information Aprilia RS250 1997 Repair Service Manual 📋 Jump to Section... 🏷️ Basic Information 👋 Introduction 📋 Manual Details 📖 Manual Coverage 📊 Manual Specifications ⚙️ Engine...

Tipo: Motorcycles

Proveedor:

SKU: 561037

Etiquetas: Aprilia Misc

Variantes de producto

Descripción

📚 Vehicle Manual Information

Aprilia RS250 1997 Repair Service Manual

🏷️ Basic Information

Identification

Make:

Aprilia

Model:

RS250

Year:

Generation

Generation Designation:

Codes

Internal Model Code:

RSV/97

👋 Introduction

Market Position

Segment:

Lightweight Supersport / Two-Stroke Performance Motorcycle

Target Audience:

Enthusiasts, private owners, professional mechanics specializing in sportbikes and performance two-strokes.

Competitive Analysis

Key Competitors:

Yamaha YZF-R6, Kawasaki Ninja ZX-6R, Suzuki GSX-R600, Honda CBR600F.

Unique Selling Proposition:

High-revving 250cc two-stroke engine derived from Suzuki RGV250 Gamma, sharp handling, racing pedigree.

Key Features

Engine Type:

Liquid-cooled, 90-degree V-twin, two-stroke

Performance Orientation:

Developed with racing input, focused on peak power and agility.

Handling Chassis:

Aluminum twin-spar frame, advanced suspension components for precise handling.

📋 Manual Details

Coverage Areas

Primary Coverage:

1997 Aprilia RS250

Page Count

Estimated Pages:

Approx. 300-400 (typical for comprehensive service manuals of this era)

Manual Type

Type:

Factory Service Manual / Repair Manual

Language

Language:

English

Format

Format:

PDF (Downloadable)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete engine disassembly, assembly, tuning, and overhaul procedures.

Fuel System:

Carburetor adjustment, cleaning, and rebuilding (Dell'Orto PHBH 28).

Ignition System:

CDI ignition system diagnostics, timing, and component testing.

Exhaust System:

Expansion chamber specifications, maintenance, and tuning considerations.

Cooling System:

Radiator, water pump, thermostat, and coolant flow diagnostics.

Transmission:

Gearbox disassembly, assembly, clutch operation, and maintenance.

Chassis Frame:

Frame inspection, alignment, and component mounting.

Suspension Front:

Front fork (Telescopic, upside-down) overhaul, oil changes, seal replacement, and damping adjustments.

Suspension Rear:

Monoshock rear suspension adjustment, linkage lubrication, and shock absorber servicing.

Brakes Front:

Dual 290mm discs with 4-piston calipers (Brembo), hydraulic system maintenance, bleeding, pad replacement.

Brakes Rear:

Single 230mm disc with 2-piston caliper (Brembo), hydraulic system maintenance, bleeding, pad replacement.

Wheels Tires:

Wheel bearing service, tire pressure recommendations, and fitment.

Electrical System:

Wiring diagrams, battery, starter, lighting, and instrument panel troubleshooting.

Bodywork Fairings:

Fairing removal, installation, and care.

Procedures Included

Maintenance Routine:

Scheduled maintenance tasks, checks, and adjustments.

Troubleshooting:

Diagnostic procedures for common performance issues and component failures.

Repair Rebuild:

Step-by-step instructions for component repair and complete system overhauls.

Special Tools:

Identification of required special tools for specific procedures.

Torque Specifications:

Detailed torque values for all critical fasteners.

Technical Depth

Depth:

Comprehensive: Covers everything from basic adjustments to full engine rebuilds and advanced electrical diagnostics.

📊 Manual Specifications

File Format

File Type:

Searchability:

Likely text-searchable (OCR processed) if digitally created or scanned with OCR.

Print Quality

Resolution:

High resolution for clear diagrams and text.

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Quality:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Liquid-cooled, 90° V-twin, two-stroke

Displacement:

249 cc

Bore X Stroke:

54.0 mm x 54.5 mm

Compression Ratio:

7.1:1 (typical, manual will confirm)

Valvetrain:

Reed valve intake, Rotary disc valve timing

Lubrication System:

Pre-mix or Automatic Oil Injection (Suzuki ATAC-like system likely)

Performance

Horsepower Peak:

Approx. 65 hp @ 11,000 rpm (factory spec, may vary)

Torque Peak:

Approx. 27 lb-ft @ 10,500 rpm (factory spec, may vary)

Fuel System

Carburetors:

2 x Dell'Orto PHBH 28 (or similar performance carbs)

Fuel Type:

Unleaded gasoline (95 RON or higher recommended)

🔧 Transmission

Standard

Type:

6-speed constant mesh

Clutch Type:

Wet, multi-plate

Optional

Optional Gear Ratios:

N/A (Typically fixed from factory, aftermarket options exist)

Features

Gear Selection:

Rotary shift drum, positive neutral finder

Final Drive:

Chain drive

📐 Dimensions

Exterior

Length:

Approx. 1940 mm (76.4 in)

Width:

Approx. 710 mm (28.0 in)

Height:

Approx. 1100 mm (43.3 in)

Wheelbase:

Approx. 1375 mm (54.1 in)

Weights

Dry Weight:

Approx. 140 kg (308.6 lbs)

Wet Weight:

Approx. 152 kg (335.1 lbs) (estimated, with fluids)

Fuel Tank Capacity:

16 Liters (4.2 US gal)

🛡️ Safety Features

Ratings

Crash Safety:

N/A (Motorcycle safety is primarily rider-dependent and component performance based).

Active Features

Braking System:

Powerful dual front disc and single rear disc with Brembo calipers offer excellent stopping power.

Suspension Stability:

Performance-oriented suspension contributes to stability during braking and cornering.

Passive Features

Lighting:

Halogen headlight, integrated front and rear turn signals.

Chassis Design:

Stiff aluminum frame provides a stable platform.

💡 Technology Features

Infotainment

Infotainment System:

None (This is a 1997 performance motorcycle, features are purely mechanical and performance-driven).

Driver Assistance

Electronic Aids:

None (No ABS, traction control, or electronic rider aids were standard on this model).

Connectivity

Connectivity Features:

🔧 Maintenance

Service Intervals

Oil Change Engine:

Every 3,000-5,000 km or annually (refer to manual for exact intervals, also check 2-stroke oil level).

Spark Plugs:

Inspect every 5,000 km, replace as needed (specific plug type recommended in manual).

Air Filter:

Clean/inspect every 5,000 km, replace as needed.

Chain Lubrication:

Lubricate every 500 km and after washing/rain.

Coolant Flush:

Every 2 years or 20,000 km (using appropriate coolant).

Fluid Specifications

Engine Oil Type:

2-Stroke pre-mix oil or specialized 2-stroke injection oil. Manual will specify grade (e.g., JASO FD or higher).

Coolant:

Ethylene glycol based antifreeze coolant, 50/50 mix with distilled water.

Brake Fluid:

DOT 4 recommended for hydraulic brake systems.

Transmission Oil:

SAE 10W-30 API SG or higher (confirm with manual).

Known Issues

Powervalve System:

Carbon buildup in the exhaust powervalve system can lead to sticking, affecting performance. Regular cleaning is crucial.

Cylinder Wear:

High-performance two-strokes can be sensitive to lean conditions and improper warm-up, potentially leading to accelerated cylinder wear.

Carburetor Tuning:

Sensitive to altitude and atmospheric changes, requiring periodic fine-tuning.

Electrical Connectors:

Corrosion or loose connections in the wiring harness can cause intermittent electrical issues.

📚 Vehicle History

Brand Heritage

Brand Focus:

Aprilia has a strong heritage in Grand Prix racing, particularly in smaller displacement classes.

Racing Influence:

The RS250 shares significant DNA with the championship-winning Aprilia RSW250 and Suzuki RGV250 Gamma race bikes.

Model Evolution

Development Basis:

Developed in collaboration with Suzuki, utilizing the potent Suzuki RGV250 Gamma's V-twin engine and chassis components.

Generations:

The 1997 model is part of the first generation (MK I), followed by the MK II with updated styling and some mechanical revisions.

Production

Production Period:

Mid-1990s to early 2000s (specific start/end dates vary by market).

Manufacturing Location:

Italy

🏆 Awards & Recognition

Recognitions

Contemporary Reviews:

Generally praised for its exceptional handling, potent engine, and sharp styling, often winning comparisons against other 600cc class bikes despite its smaller displacement.

Track Performance:

Highly regarded for its track day performance and racing potential, a favorite among club racers.

Certifications

Emissions Standards:

N/A (Designed before strict emissions regulations for performance motorcycles were fully implemented).

🏆 Professional Vehicle Manual Information

Comprehensive technical documentation for maintenance, repair, and operation