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1998 Aprilia RS250 Factory Service Repair Manual
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Basic Information Identification Make: Aprilia Model: RS250 Year: 1998 Generation Generation Identifier: MK1 (First Generation) Codes Chassis Code Prefix: AP02 Introduction Market Position Segment: High-performance 250cc sportbike Target Audience: Enthusiasts,...
Type: Motorcycles
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Sku: 549484
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| Basic Information | |
| Identification | |
| Make: | Aprilia |
| Model: | RS250 |
| Year: | 1998 |
| Generation | |
| Generation Identifier: | MK1 (First Generation) |
| Codes | |
| Chassis Code Prefix: | AP02 |
| Introduction | |
| Market Position | |
| Segment: | High-performance 250cc sportbike |
| Target Audience: | Enthusiasts, track day riders, performance-oriented street riders |
| Competitive Analysis | |
| Key Competitors: | Yamaha YZF-R6, Honda CBR250RR, Kawasaki ZX-2R, Suzuki GSX-R250 |
| Key Features | |
| Engine Heritage: | Derived from the Suzuki RGV250's V-twin 2-stroke engine, renowned for its power and handling. |
| Chassis Design: | Aluminium twin-spar frame offering excellent rigidity and agility. |
| Performance Focus: | Designed for track performance and spirited road riding, emphasizing light weight and a potent power-to-weight ratio. |
| Manual Details | |
| Coverage Areas | |
| Primary Coverage: | Comprehensive service and repair procedures |
| Secondary Coverage: | Maintenance, diagnostics, troubleshooting, electrical systems, chassis components |
| Page Count | |
| Estimated Pages: | Approximately 300-400 (typical for this era and type of manual) |
| Manual Type | |
| Type: | Factory Service Repair Manual |
| Language | |
| Language: | English |
| Format | |
| Format: | Digital (PDF - INSTANT DOWNLOAD) |
| Manual Coverage | |
| Systems Covered | |
| Engine Mechanical: | Top End (Cylinders, Pistons, Rings), Bottom End (Crankshaft, Connecting Rods), Crankcase, Sealing, Lubrication System |
| Fuel System: | Carburetors (Mikuni TMX), Fuel Tank, Fuel Lines, Fuel Pump (if applicable), Fuel Filter |
| Ignition System: | Ignition Coils, CDI Unit, Spark Plugs, Wiring Harness |
| Cooling System: | Radiator, Hoses, Water Pump, Thermostat, Coolant Specifications |
| Exhaust System: | Expansion Chambers, Silencers, Clamps, Gaskets |
| Transmission Drivetrain: | Gearbox (Internal Components), Clutch (Wet Multi-Plate), Clutch Actuation, Drive Chain, Sprockets |
| Brakes: | Front and Rear Hydraulic Systems, Calipers, Master Cylinders, Brake Lines, Brake Pads, Discs, Fluid Specifications |
| Suspension: | Front Forks (Inverted Telescopic, Cartridge Type), Rear Shock Absorber (Monoshock), Linkages, Spring Rates, Oil Specifications |
| Steering: | Handlebars, Steering Stem Bearings, Triple Clamps |
| Wheels Tires: | Wheel Bearings, Wheel Types, Tire Sizes, Tire Pressures |
| Electrical System: | Lighting (Headlight, Taillight, Indicators), Battery, Fuses, Relays, Wiring Diagrams, Switches, Instrumentation |
| Bodywork Chassis: | Frame, Fairings, Seat, Fuel Tank Mounting, Subframe |
| Procedures Included | |
| Routine Maintenance: | Oil Changes, Filter Replacements, Chain Adjustment and Lubrication, Brake Pad Inspection, Tire Pressure Checks, Coolant Level Checks |
| Engine Rebuild: | Top End Rebuild (Piston and Ring Replacement), Cylinder Head Overhaul, Crankshaft and Bearing Replacement (Full Engine Rebuild) |
| Carburetor Service: | Removal, Disassembly, Cleaning, Reassembly, Jetting and Tuning Recommendations, Float Level Adjustment |
| Suspension Service: | Fork Oil Change and Level Adjustment, Fork Seal Replacement, Rear Shock Absorber Servicing, Linkage Bearing Maintenance |
| Brake System Service: | Brake Fluid Flush and Replacement, Caliper Rebuild, Master Cylinder Overhaul, Pad and Disc Replacement |
| Clutch Service: | Clutch Plate Replacement, Clutch Lever and Cable Adjustment, Clutch Cover Gasket Replacement |
| Electrical Diagnostics: | Troubleshooting Electrical Faults, Wiring Diagram Interpretation, Component Testing |
| Troubleshooting Guides: | Systematic Diagnosis of Common Problems, Symptom-Based Troubleshooting |
| Technical Depth | |
| Depth: | Comprehensive, covering everything from basic maintenance to complete engine and chassis overhauls. |
| Diagnostic Capability: | Includes diagnostic procedures for electrical and mechanical systems. |
| Specifications Detail: | Detailed torque specifications, clearances, fluid capacities, and electrical values. |
| Manual Specifications | |
| File Format | |
| File Type: | |
| Searchable Text: | Likely searchable text, enhancing usability. |
| Print Quality | |
| Image Resolution: | High resolution for clear diagrams and images. |
| Diagram Clarity: | Clear, detailed exploded views and wiring diagrams. |
| Binding Type | |
| Binding: | N/A (Digital Download) |
| Paper Type | |
| Paper Type: | N/A (Digital Download) |
| Engine Specifications | |
| Primary Engine | |
| Engine Type: | Liquid-cooled, 2-stroke, V-twin |
| Displacement: | 249 cc |
| Bore X Stroke: | 54.0 mm x 54.5 mm |
| Compression Ratio: | 7.5:1 (Typical for this model, check manual for exact spec) |
| Valve Mechanism: | Reed valve induction, powervalves (Suzuki APEX V) |
| Lubrication: | Separate oil injection system |
| Performance | |
| Horsepower Claimed: | Approx. 70-75 HP (at crankshaft) - check manual for exact figure |
| Torque Claimed: | Approx. 38-40 Nm (at crankshaft) - check manual for exact figure |
| Fuel System | |
| Carburetors: | 2 x Mikuni TMX30 Flat-slide Carburetors |
| Fuel Type: | Unleaded gasoline (min. 95 RON) |
| Fuel Tank Capacity: | 16 Liters |
| Transmission | |
| Standard | |
| Transmission Type: | 6-speed constant mesh, sequential |
| Clutch Type: | Wet, multi-plate |
| Features | |
| Gear Ratios: | Specific ratios detailed in manual (e.g., 1st: 2.750, 2nd: 2.063, 3rd: 1.583, 4th: 1.333, 5th: 1.143, 6th: 1.000 - typical values, check manual) |
| Final Drive: | Chain driven (DID 520 VMX or similar) |
| Dimensions | |
| Exterior | |
| Length: | Approx. 2010 mm (check manual for exact) |
| Width: | Approx. 720 mm (check manual for exact) |
| Height: | Approx. 1120 mm (check manual for exact) |
| Wheelbase: | Approx. 1375 mm (check manual for exact) |
| Weights | |
| Dry Weight: | Approx. 142 kg (check manual for exact) |
| Wet Weight: | Approx. 165 kg (with fluids, check manual for exact) |
| Safety Features | |
| Ratings | |
| Crash Test Ratings: | N/A (Motorcycle, no official ratings as per automotive standards) |
| Active Features | |
| Braking System: | Dual front disc brakes, single rear disc brake with hydraulic actuation. |
| Tire Adhesion: | Emphasis on high-grip sportbike tires for optimal cornering and braking. |
| Passive Features | |
| Chassis Integrity: | Sturdy aluminium frame designed for rider safety in dynamic situations. |
| Rider Ergonomics: | Sportbike riding position, designed for rider control and connection to the machine. |
| Technology Features | |
| Infotainment | |
| Infotainment System: | N/A (basic analogue instrumentation) |
| Driver Assistance | |
| Driver Assistance Features: | N/A (performance-focused sportbike) |
| Connectivity | |
| Connectivity Features: | N/A |
| Instrumentation | |
| Dashboard Layout: | Analogue speedometer, tachometer, coolant temperature gauge, indicator lights. |
| Lighting | |
| Headlight Type: | Halogen (dual bulb typically) |
| Maintenance | |
| Service Intervals | |
| Oil Change Engine Oil: | Every 3,000 - 5,000 km or annually (check manual for specific 2-stroke oil type and interval) |
| Spark Plug Inspection Replacement: | Every 5,000 - 8,000 km (check manual for plug type and gap) |
| Chain Adjustment Lubrication: | Every 500 - 1,000 km and after washing/wet riding |
| Brake Fluid Flush Replacement: | Every 2 years or as needed (DOT 4 recommended) |
| Coolant Flush Replacement: | Every 2 years (using appropriate motorcycle coolant) |
| Fluid Specifications | |
| Engine Oil Type: | High-quality 2-stroke motorcycle oil, API TC or JASO FD rated (check manual for specific brand/grade recommendations) |
| Transmission Oil Type: | SAE 10W-40 motorcycle gear oil (check manual for exact specification and capacity) |
| Brake Fluid Type: | DOT 4 |
| Fork Oil Type Viscosity: | Specific viscosity and level detailed in manual (e.g., Showa SS-8 or equivalent, 5W-10W) |
| Known Issues | |
| Common Wear Items: | Exhaust power valves (carbon build-up, sticking), crankcase seals, clutch plates, steering head bearings. |
| Carburetor Issues: | Tuning sensitivity to altitude and temperature, float bowl leaks if not maintained. |
| Engine Management: | Importance of proper premixing if oil injection system is bypassed, or ensuring oil injection system is functioning correctly. |
| Vehicle History | |
| Brand Heritage | |
| Manufacturer: | Aprilia (Italian motorcycle manufacturer known for racing success) |
| Model Evolution | |
| Rs250 Lineage: | Successor to models like the AF1 Futura and Classic, and heavily based on the Suzuki RGV250 Gamma platform. |
| Generation Notes: | The 1998 model represents the initial iteration of the RS250, refined from its Suzuki underpinnings. |
| Production | |
| Production Period: | 1995-2003 (across various iterations and minor updates) |
| Manufacturing Location: | Italy |
| Awards & Recognition | |
| Recognitions | |
| Performance Acclaim: | Widely praised for its handling and a potent 2-stroke engine in its class. |
| Ratings | |
| Motorcycle Reviews: | Consistently rated highly by motorcycle publications for its agility and performance on twisty roads and tracks. |