Aprilia RS250 RS 250 945W 1998 Factory Service Repair Manual
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🏷️ Basic Information Identification Make: Aprilia Model: RS250 Year: 1998 Codes Internal Model Code: 945W 👋 Introduction Market Position Positioning: The Aprilia RS250 was a high-performance, race-derived sportbike that competed directly with other 250cc two-stroke sportbikes of its era, offering exceptional handling and a potent engine. Competitive Analysis Competitors: Suzuki RGV250, Yamaha TZR250, Honda NSR250 Key Features Handling: Renowned for its agile chassis and superb handling characteristics, derived from Aprilia's Grand Prix racing experience. Engine Type: V-twin, liquid-cooled, two-stroke engine known for its powerband and distinctive sound. Manual Utility Utility: Essential for owners and technicians to maintain, diagnose, and repair the Aprilia RS250 effectively, ensuring optimal performance and longevity. 📋 Manual Details Coverage Areas Primary Coverage: Full Factory Service Repair Scope: Complete diagnosis, repair, maintenance, and specifications Page Count Estimated Pages: Hundreds of pages (specific count not provided, but described as comprehensive) Manual Type Type: Factory Service Repair Manual Language Language: English (assumed for typical North American market manuals, but confirmed upon purchase) Format Format: Downloadable PDF 📖 Manual Coverage Systems Covered Engine: Full engine overhaul, disassembly, reassembly, tuning, lubrication system, cooling system, fuel delivery, ignition system, exhaust system Transmission: Gearbox overhaul, clutch service, shift mechanism, lubrication Chassis: Frame inspection and repair, suspension (front forks, rear shock absorber), steering system, wheel bearings, swingarm Brakes: Front and rear brake system service, caliper overhaul, master cylinder service, fluid replacement, bleeding procedures, disc and pad inspection Electrical: Wiring diagrams, lighting system, ignition system components, charging system, battery service, starter motor, fuses, relays, diagnostic procedures Bodywork: Fairing removal and installation, seat, fuel tank, body panel alignment, minor body repairs Procedures Included Maintenance: Scheduled maintenance intervals, fluid changes (oil, coolant, brake fluid), filter replacements, chain adjustment, general inspections Troubleshooting: Diagnostic flowcharts, common problems and their solutions, symptom-based troubleshooting guides Repair: Step-by-step repair instructions for all major components, including engine rebuilds, transmission overhauls, and suspension repairs Technical Data: Torque specifications, clearances, timing settings, electrical resistance values, diagnostic codes Technical Depth Depth: Comprehensive. Covers everything from basic user maintenance to complete engine and transmission rebuilds, including advanced diagnostics and electrical troubleshooting. 📊 Manual Specifications File Format Format: PDF Print Quality Quality: High-resolution, suitable for printing individual pages or the entire manual. Binding Type Binding: N/A (Digital Download - PDF) Paper Type Paper Type: N/A (Digital Download - PDF) ⚙️ Engine Specifications Primary Engine Configuration: V-twin (90-degree) Displacement: 249 cc Bore X Stroke: 54 x 54.5 mm Cooling System: Liquid-cooled Induction: Reed valve induction Performance Horsepower: Approximately 70-75 hp at the crankshaft (depending on market restrictions) Torque: Approximately 45 Nm (33 lb-ft) Redline: Around 11,500 rpm Fuel System Carburetors: Twin Mikuni TM34 flat-slide carburetors Fuel Type: Unleaded gasoline (minimum 95 RON/91 AKI recommended) Lubrication System: Autolube (automatic oil injection) Oil Type: 2-stroke synthetic oil (e.g., Motul 800 2T Factory Line, Castrol TTS) Ignition System: Digital CDI 🔧 Transmission Standard Type: 6-speed manual constant mesh Features Clutch: Wet multi-plate Final Drive: Chain drive Transmission Oil Type: 2-stroke engine oil (mixed with fuel) Gearbox Oil Type: API GL-4 75W-90 or 80W-90 gear oil (check manual for specific specifications) 📐 Dimensions Exterior Length: Approximately 1980 mm (78 in) Width: Approximately 720 mm (28.3 in) Height: Approximately 1130 mm (44.5 in) Wheelbase: Approximately 1370 mm (53.9 in) Weights Dry Weight: Approximately 130 kg (286.6 lbs) Wet Weight: Approximately 147 kg (324 lbs) Fuel Capacity: 16 Liters (4.2 US gallons) 🛡️ Safety Features Ratings Safety Ratings: N/A (Motorcycles generally do not receive crash test ratings like cars) Active Features Braking System: Dual front discs, single rear disc. High-performance braking components. Suspension Performance: Adjustable front forks (preload, compression, rebound) and rear shock absorber contribute to stability and control. Passive Features Frame Construction: Aluminum twin-spar frame provides rigidity and stability. 💡 Technology Features Infotainment Infotainment System: N/A (Focus is on performance, not rider comfort/infotainment features of modern bikes). Driver Assistance Assistance Features: N/A (No electronic rider aids like ABS or traction control found on this model). Engine Management Engine Management Features: Digital CDI ignition system with electronically controlled power valve (RSV) for optimized power delivery across the rev range. 🔧 Maintenance Service Intervals Oil Change Engine: Check 2-stroke oil reservoir regularly. Engine oil (gearbox) typically checked at 6,000 km or annually. Refer to manual for specific intervals. Spark Plug Replacement: Refer to manual; typically around 6,000-12,000 km depending on usage and plug type. Chain Lubrication Adjustment: Lubricate chain every 500 km or after riding in wet conditions. Adjust slack as per manual specifications (e.g., 20-30mm). Coolant Replacement: Every 2 years or as per manual recommendations. Fluid Specifications Engine Oil Type: High-quality 2-stroke synthetic oil for autolube system (e.g., Motul 800, Castrol A747). Gearbox Oil Type: API GL-4 75W-90 or 80W-90 gear oil. Brake Fluid Type: DOT 4 or DOT 5.1 (check manual for specific recommendation and compatibility). Coolant Type: Ethylene glycol-based coolant with anti-corrosion additives,...
The Aprilia RS250 was a high-performance, race-derived sportbike that competed directly with other 250cc two-stroke sportbikes of its era, offering exceptional handling and a potent engine.
Competitive Analysis
Competitors:
Suzuki RGV250, Yamaha TZR250, Honda NSR250
Key Features
Handling:
Renowned for its agile chassis and superb handling characteristics, derived from Aprilia's Grand Prix racing experience.
Engine Type:
V-twin, liquid-cooled, two-stroke engine known for its powerband and distinctive sound.
Manual Utility
Utility:
Essential for owners and technicians to maintain, diagnose, and repair the Aprilia RS250 effectively, ensuring optimal performance and longevity.
📋 Manual Details
Coverage Areas
Primary Coverage:
Full Factory Service Repair
Scope:
Complete diagnosis, repair, maintenance, and specifications
Page Count
Estimated Pages:
Hundreds of pages (specific count not provided, but described as comprehensive)
Manual Type
Type:
Factory Service Repair Manual
Language
Language:
English (assumed for typical North American market manuals, but confirmed upon purchase)
Format
Format:
Downloadable PDF
📖 Manual Coverage
Systems Covered
Engine:
Full engine overhaul, disassembly, reassembly, tuning, lubrication system, cooling system, fuel delivery, ignition system, exhaust system
Comprehensive. Covers everything from basic user maintenance to complete engine and transmission rebuilds, including advanced diagnostics and electrical troubleshooting.
📊 Manual Specifications
File Format
Format:
PDF
Print Quality
Quality:
High-resolution, suitable for printing individual pages or the entire manual.
Binding Type
Binding:
N/A (Digital Download - PDF)
Paper Type
Paper Type:
N/A (Digital Download - PDF)
⚙️ Engine Specifications
Primary Engine
Configuration:
V-twin (90-degree)
Displacement:
249 cc
Bore X Stroke:
54 x 54.5 mm
Cooling System:
Liquid-cooled
Induction:
Reed valve induction
Performance
Horsepower:
Approximately 70-75 hp at the crankshaft (depending on market restrictions)
Torque:
Approximately 45 Nm (33 lb-ft)
Redline:
Around 11,500 rpm
Fuel System
Carburetors:
Twin Mikuni TM34 flat-slide carburetors
Fuel Type:
Unleaded gasoline (minimum 95 RON/91 AKI recommended)
API GL-4 75W-90 or 80W-90 gear oil (check manual for specific specifications)
📐 Dimensions
Exterior
Length:
Approximately 1980 mm (78 in)
Width:
Approximately 720 mm (28.3 in)
Height:
Approximately 1130 mm (44.5 in)
Wheelbase:
Approximately 1370 mm (53.9 in)
Weights
Dry Weight:
Approximately 130 kg (286.6 lbs)
Wet Weight:
Approximately 147 kg (324 lbs)
Fuel Capacity:
16 Liters (4.2 US gallons)
🛡️ Safety Features
Ratings
Safety Ratings:
N/A (Motorcycles generally do not receive crash test ratings like cars)
Active Features
Braking System:
Dual front discs, single rear disc. High-performance braking components.
Suspension Performance:
Adjustable front forks (preload, compression, rebound) and rear shock absorber contribute to stability and control.
Passive Features
Frame Construction:
Aluminum twin-spar frame provides rigidity and stability.
💡 Technology Features
Infotainment
Infotainment System:
N/A (Focus is on performance, not rider comfort/infotainment features of modern bikes).
Driver Assistance
Assistance Features:
N/A (No electronic rider aids like ABS or traction control found on this model).
Engine Management
Engine Management Features:
Digital CDI ignition system with electronically controlled power valve (RSV) for optimized power delivery across the rev range.
🔧 Maintenance
Service Intervals
Oil Change Engine:
Check 2-stroke oil reservoir regularly. Engine oil (gearbox) typically checked at 6,000 km or annually. Refer to manual for specific intervals.
Spark Plug Replacement:
Refer to manual; typically around 6,000-12,000 km depending on usage and plug type.
Chain Lubrication Adjustment:
Lubricate chain every 500 km or after riding in wet conditions. Adjust slack as per manual specifications (e.g., 20-30mm).
Coolant Replacement:
Every 2 years or as per manual recommendations.
Fluid Specifications
Engine Oil Type:
High-quality 2-stroke synthetic oil for autolube system (e.g., Motul 800, Castrol A747).
Gearbox Oil Type:
API GL-4 75W-90 or 80W-90 gear oil.
Brake Fluid Type:
DOT 4 or DOT 5.1 (check manual for specific recommendation and compatibility).
Coolant Type:
Ethylene glycol-based coolant with anti-corrosion additives, mixed 50/50 with distilled water.
Known Issues
Cylinder Wear:
Can be susceptible to wear, especially if not properly maintained or if the engine is consistently run hard without adequate cooling. Regular inspection of compression is recommended.
Power Valve Issues:
The power valve system (RSV) can accumulate carbon deposits, leading to sticky operation or failure to open/close correctly. Requires periodic cleaning and servicing.
Carburator Tuning:
Mikuni TM34 carburetors can be sensitive to altitude and temperature changes, often requiring re-jetting or adjustment for optimal performance and fuel efficiency.
Electrical Connections:
Older bikes can suffer from corroded electrical connectors, leading to intermittent issues with ignition or lights. Cleaning and dielectric grease application is advised.
Clutch Slippage:
Can occur with high mileage or aggressive use. Clutch plates may need replacement.
📚 Vehicle History
Brand Heritage
Heritage:
Aprilia has a rich history in motorcycle racing, particularly in the Grand Prix circuit, which heavily influenced the design and performance of its road-going sportbikes like the RS250.
Model Evolution
Development Basis:
The RS250 was developed using technology and components from Aprilia's successful Grand Prix race bikes, and its engine was based on the Suzuki RG250 Gamma.
Production
Production Years:
1995-2003
Manufacturing Location:
Italy
🏆 Awards & Recognition
Recognitions
Recognition:
While specific awards for the 1998 model are not widely documented, the Aprilia RS250 line was critically acclaimed for its exceptional handling and performance in its class, often being cited as a benchmark sportbike.
Ratings
Performance Ratings:
Consistently rated highly by motorcycle publications for its track-day capability and thrilling ride.
Certifications
Emissions Certification:
Meets emissions standards of its respective market year; specific certifications would be detailed in the manual.