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Aprilia RS 250 1997 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Aprilia Model: RS 250 Year: 1997 Codes Internal Code: RS250_1997_FSM 👋 Introduction Market Position Classification: High-performance, track-oriented supersport motorcycle. Competitive Analysis Key Competitors: Yamaha YZF-R6, Honda CBR600F3, Suzuki GSX-R600 (all from the mid-to-late 1990s). Key Features Engine Layout: Lightweight, high-revving V-twin engine derived from Suzuki RG500 Gamma GP racer. Design Philosophy: Focus on agility, sharp handling, and racetrack performance. Target Audience User Profile: Enthusiast riders, track day participants, and mechanics specializing in sportbikes. 📋 Manual Details Coverage Areas Manual Scope: Comprehensive workshop procedures, electrical diagrams, torque settings, fluid capacities. Page Count Estimated Pages: Extensive (exact count not provided, but described as 'complete' and 'packed with all information') Manual Type Type: Factory Service Repair Manual Language Language: English (implied by product description and common for service manuals) Format Format: PDF 📖 Manual Coverage Systems Covered Engine: Complete engine overhaul, diagnosis, and tuning procedures. Fuel And Lubrication System: Carburetor tuning, fuel system maintenance, lubrication specifications, oil pump operation. Cooling System: Radiator, water pump, thermostat, coolant specifications, bleeding procedures. Electrical System: Full electrical schematics, wiring diagrams, component testing, ignition system, lighting, battery. Chassis: Frame inspection, suspension system (front and rear), steering system, wheel bearings. Brakes: Brake system diagnosis, caliper overhaul, pad replacement, fluid specifications, bleeding. Bodywork: Fairing removal and installation, component adjustments. Procedures Included Maintenance: Periodic maintenance schedules, tune-up procedures, fluid changes, filter replacements. Troubleshooting: Diagnostic guides for common problems, symptom-based troubleshooting. Repair: Step-by-step instructions for component removal, overhaul, and reassembly. Adjustments: Carburetor synchronization, clutch adjustment, chain adjustment. Specifications: Torque settings for all fasteners, fluid capacities, wear limits. Technical Depth Depth: Full workshop level, covering everything from basic maintenance to complete engine and chassis rebuilds. 📊 Manual Specifications File Format Requirements: Adobe PDF Reader & WinZip Viewing Features: Zoom In/Out functionality Compatibility: All Versions of Windows & Mac Print Quality Printability: Printable (implied for workshop use) Binding Type Binding: Digital (PDF) Paper Type Paper Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 2-stroke, V-twin Displacement: 249 cc Bore X Stroke: 54 mm x 54.5 mm Compression Ratio: 7.8:1 Ignition System: Digital CDI Performance Horsepower Output: Approx. 70 hp @ 11,000 rpm (specific to region and tuning) Torque Output: Approx. 30 lb-ft @ 10,000 rpm (specific to region and tuning) Fuel System Carburetors: Dual Mikuni TM34SS flat-slide carburetors Fuel Type: Unleaded gasoline (minimum 95 RON or 91 AKI recommended) Fuel Capacity: 16 Liters (4.2 US gallons) Lubrication Oil Type: 2-stroke synthetic oil (specific API TC or JASO FD rated) Oil Injection: Automatic oil injection system 🔧 Transmission Standard Type: 6-speed sequential, constant mesh Features Clutch Type: Wet, multi-plate, cable-actuated Final Drive: Chain driven 📐 Dimensions Exterior Length: Approx. 1960 mm (77.2 in) Width: Approx. 730 mm (28.7 in) Height: Approx. 1120 mm (44.1 in) Wheelbase: Approx. 1370 mm (53.9 in) Weights Dry Weight: Approx. 142 kg (313 lbs) Wet Weight: Approx. 165 kg (364 lbs) (with fluids) Suspension Front Suspension: 41mm upside-down telescopic fork (e.g., Marzocchi M1 or Showa) Rear Suspension: Monoshock, adjustable (e.g., Sachs or Showa) Brakes Front Brakes: Dual 320mm discs, 4-piston calipers (e.g., Nissin or Brembo) Rear Brakes: Single 240mm disc, 2-piston caliper Wheels Tires Front Wheel Size: 17 inch Rear Wheel Size: 17 inch Front Tire Size: 120/70ZR17 Rear Tire Size: 160/60ZR17 🛡️ Safety Features Ratings Safety Features: N/A (Motorcycles typically do not have standardized crash ratings like cars; focus is on rider safety through chassis and braking design). Active Features Braking System: Dual front disc brakes with four-piston calipers for strong stopping power. Passive Features Frame Construction: Aluminum twin-spar frame for rigidity and stability. 💡 Technology Features Infotainment Features: N/A (This era of sportbike focused on performance, not infotainment). Driver Assistance Features: N/A (No electronic rider aids like ABS or traction control were standard on this model). Engine Management Power Valves: Features an electronic power valve system for improved power delivery across the rev range. Ignition Timing: Advanced digital CDI ignition with variable timing for optimal combustion. 🔧 Maintenance Service Intervals Oil Change Interval: Refer to manual for specific mileage/time intervals; typically every 3,000-5,000 km (1,800-3,000 miles) for engine oil. Spark Plug Replacement: Recommended every 5,000-10,000 km (3,000-6,000 miles), consult manual for specific type and gap. Chain Lubrication Tension: Frequent checks and lubrication recommended, typically every 500-1,000 km (300-600 miles). Fluid Specifications Engine Oil Type: API TC or JASO FD rated 2-stroke synthetic oil. Coolant Type: Ethylene glycol-based coolant with corrosion inhibitors, typically a 50/50 mix with distilled water. Brake Fluid Type: DOT 4 or DOT 5.1 (check manual for exact specification and change interval, typically every 2 years). Transmission Oil Type: Specific gear oil for wet clutches (e.g., SAE 10W-40 or 10W-50 motorcycle specific). Known Issues Common Wear Items: 2-stroke engines require diligent maintenance of power valves, reed valves, and exhaust systems. Clutch wear, suspension seals, and electrical connections...
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Aprilia RS 250 1997 Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
RS 250
Year:
1997
Codes
Internal Code:
RS250_1997_FSM
👋 Introduction
Market Position
Classification:
High-performance, track-oriented supersport motorcycle.
Competitive Analysis
Key Competitors:
Yamaha YZF-R6, Honda CBR600F3, Suzuki GSX-R600 (all from the mid-to-late 1990s).
Key Features
Engine Layout:
Lightweight, high-revving V-twin engine derived from Suzuki RG500 Gamma GP racer.
Design Philosophy:
Focus on agility, sharp handling, and racetrack performance.
Target Audience
User Profile:
Enthusiast riders, track day participants, and mechanics specializing in sportbikes.
📋 Manual Details
Coverage Areas
Manual Scope:
Comprehensive workshop procedures, electrical diagrams, torque settings, fluid capacities.
Page Count
Estimated Pages:
Extensive (exact count not provided, but described as 'complete' and 'packed with all information')
Manual Type
Type:
Factory Service Repair Manual
Language
Language:
English (implied by product description and common for service manuals)
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine:
Complete engine overhaul, diagnosis, and tuning procedures.
Fuel And Lubrication System:
Carburetor tuning, fuel system maintenance, lubrication specifications, oil pump operation.
Cooling System:
Radiator, water pump, thermostat, coolant specifications, bleeding procedures.
Electrical System:
Full electrical schematics, wiring diagrams, component testing, ignition system, lighting, battery.
Chassis:
Frame inspection, suspension system (front and rear), steering system, wheel bearings.
Brakes:
Brake system diagnosis, caliper overhaul, pad replacement, fluid specifications, bleeding.
Bodywork:
Fairing removal and installation, component adjustments.
Procedures Included
Maintenance:
Periodic maintenance schedules, tune-up procedures, fluid changes, filter replacements.
Troubleshooting:
Diagnostic guides for common problems, symptom-based troubleshooting.
Repair:
Step-by-step instructions for component removal, overhaul, and reassembly.
Adjustments:
Carburetor synchronization, clutch adjustment, chain adjustment.
Specifications:
Torque settings for all fasteners, fluid capacities, wear limits.
Technical Depth
Depth:
Full workshop level, covering everything from basic maintenance to complete engine and chassis rebuilds.
📊 Manual Specifications
File Format
Requirements:
Adobe PDF Reader & WinZip
Viewing Features:
Zoom In/Out functionality
Compatibility:
All Versions of Windows & Mac
Print Quality
Printability:
Printable (implied for workshop use)
Binding Type
Binding:
Digital (PDF)
Paper Type
Paper Type:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, 2-stroke, V-twin
Displacement:
249 cc
Bore X Stroke:
54 mm x 54.5 mm
Compression Ratio:
7.8:1
Ignition System:
Digital CDI
Performance
Horsepower Output:
Approx. 70 hp @ 11,000 rpm (specific to region and tuning)
Torque Output:
Approx. 30 lb-ft @ 10,000 rpm (specific to region and tuning)
Fuel System
Carburetors:
Dual Mikuni TM34SS flat-slide carburetors
Fuel Type:
Unleaded gasoline (minimum 95 RON or 91 AKI recommended)
Fuel Capacity:
16 Liters (4.2 US gallons)
Lubrication
Oil Type:
2-stroke synthetic oil (specific API TC or JASO FD rated)
Oil Injection:
Automatic oil injection system
🔧 Transmission
Standard
Type:
6-speed sequential, constant mesh
Features
Clutch Type:
Wet, multi-plate, cable-actuated
Final Drive:
Chain driven
📐 Dimensions
Exterior
Length:
Approx. 1960 mm (77.2 in)
Width:
Approx. 730 mm (28.7 in)
Height:
Approx. 1120 mm (44.1 in)
Wheelbase:
Approx. 1370 mm (53.9 in)
Weights
Dry Weight:
Approx. 142 kg (313 lbs)
Wet Weight:
Approx. 165 kg (364 lbs) (with fluids)
Suspension
Front Suspension:
41mm upside-down telescopic fork (e.g., Marzocchi M1 or Showa)
Rear Suspension:
Monoshock, adjustable (e.g., Sachs or Showa)
Brakes
Front Brakes:
Dual 320mm discs, 4-piston calipers (e.g., Nissin or Brembo)
Rear Brakes:
Single 240mm disc, 2-piston caliper
Wheels Tires
Front Wheel Size:
17 inch
Rear Wheel Size:
17 inch
Front Tire Size:
120/70ZR17
Rear Tire Size:
160/60ZR17
🛡️ Safety Features
Ratings
Safety Features:
N/A (Motorcycles typically do not have standardized crash ratings like cars; focus is on rider safety through chassis and braking design).
Active Features
Braking System:
Dual front disc brakes with four-piston calipers for strong stopping power.
Passive Features
Frame Construction:
Aluminum twin-spar frame for rigidity and stability.
💡 Technology Features
Infotainment
Features:
N/A (This era of sportbike focused on performance, not infotainment).
Driver Assistance
Features:
N/A (No electronic rider aids like ABS or traction control were standard on this model).
Engine Management
Power Valves:
Features an electronic power valve system for improved power delivery across the rev range.
Ignition Timing:
Advanced digital CDI ignition with variable timing for optimal combustion.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Refer to manual for specific mileage/time intervals; typically every 3,000-5,000 km (1,800-3,000 miles) for engine oil.
Spark Plug Replacement:
Recommended every 5,000-10,000 km (3,000-6,000 miles), consult manual for specific type and gap.
Chain Lubrication Tension:
Frequent checks and lubrication recommended, typically every 500-1,000 km (300-600 miles).
Fluid Specifications
Engine Oil Type:
API TC or JASO FD rated 2-stroke synthetic oil.
Coolant Type:
Ethylene glycol-based coolant with corrosion inhibitors, typically a 50/50 mix with distilled water.
Brake Fluid Type:
DOT 4 or DOT 5.1 (check manual for exact specification and change interval, typically every 2 years).
Transmission Oil Type:
Specific gear oil for wet clutches (e.g., SAE 10W-40 or 10W-50 motorcycle specific).
Known Issues
Common Wear Items:
2-stroke engines require diligent maintenance of power valves, reed valves, and exhaust systems. Clutch wear, suspension seals, and electrical connections can also be points of attention.
Tuning Sensitivity:
Highly sensitive to carburetor settings, jetting, and exhaust condition for optimal performance and engine longevity.
📚 Vehicle History
Brand Heritage
Manufacturer:
Aprilia is an Italian manufacturer renowned for its success in motorcycle racing, particularly in the Grand Prix circuit.
Model Evolution
Development Basis:
The RS 250's development was heavily influenced by Suzuki's RGV250 Gamma and the legendary RG500 Gamma GP machines.
Racing Connection:
Engine technology and chassis design share DNA with Aprilia's own successful GP race bikes.
Production
Production Years:
1995 - 2003
Manufacturing Location:
Noale, Italy
🏆 Awards & Recognition
Recognitions
Period Reputation:
Widely regarded by enthusiasts as one of the best handling and most engaging 250cc sportbikes of its era.
Racing Success:
Aprilia achieved significant success in 125cc and 250cc Grand Prix racing, with the RS 250 benefiting from this racing pedigree.
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