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1998 APRILIA RS250 Service Repair Manual

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🏷️ Basic Information Identification Make: Aprilia Model: RS250 Year: 1998 Codes Engine Code: Rotax 2-stroke V-twin 👋 Introduction Market Position Market Position: The Aprilia RS250 was positioned as a high-performance, track-inspired supersport motorcycle, competing with other 250cc two-stroke performance machines of its era. Competitive Analysis Competitors: Key competitors included models like the Yamaha YZF-R25, Kawasaki Ninja ZX-25R (later models), and Suzuki RGV250. Key Features Key Features: Lightweight chassis, potent V-twin two-stroke engine, advanced suspension, and aggressive styling. Target Audience: Enthusiasts and riders seeking a thrilling, agile, and track-capable motorcycle. 📋 Manual Details Coverage Areas Manual Type: Complete Service and Repair Manual Language: English Format: Likely digital (PDF) or printed bound manual Page Count: Comprehensive (typically 300-500 pages for a full service manual) 📖 Manual Coverage Systems Covered Engine: Top-end rebuild, bottom-end assembly, cooling system, lubrication, fuel delivery, ignition, exhaust Transmission: Clutch operation, gear selection, gearbox disassembly and assembly, lubrication Chassis: Frame inspection, suspension (front forks, rear shock), steering system, wheel bearings, swingarm Brakes: Front and rear brake system maintenance, hydraulic components, pad replacement, bleeding procedures Electrical: Wiring diagrams, lighting, ignition system, charging system, battery, starter motor, diagnostic troubleshooting Fuel System: Carburetor tuning and overhaul (Mikuni T-series), fuel tank, fuel lines, fuel pump (if applicable) Procedures Included Maintenance: Regular scheduled maintenance, oil changes, filter replacements, chain adjustment, spark plug service Troubleshooting: Diagnostic flowcharts for common problems, electrical troubleshooting guides, performance issues Repair: Detailed step-by-step instructions for component disassembly, repair, and reassembly Technical Specifications: Torque specifications, clearances, fluid capacities, electrical resistance values Technical Depth Depth: Comprehensive, covering from basic user maintenance to in-depth engine and transmission overhauls, suitable for professional technicians and advanced home mechanics 📊 Manual Specifications File Format File Format: Likely PDF with searchable text for digital versions, high-quality print for physical copies Print Quality Print Quality: High-resolution images and clear diagrams Binding Type Binding Type: Professional binding (e.g., perfect binding, spiral binding) for longevity and ease of use in a workshop environment Paper Type Paper Type: Durable, potentially glossy paper to withstand workshop conditions and protect against oil and grime. ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 90-degree V-twin, two-stroke Displacement: 249.3 cc (250cc class) Bore X Stroke: 54.0 mm x 54.5 mm Power Delivery: Known for strong mid-range and top-end power delivery, characteristic of performance two-strokes. Performance Horsepower: Approximately 70-75 HP (varies by region and specific tuning, often stated in the 70s HP range for homologation specials) Torque: Approximately 40-45 Nm (Newton-meters) Fuel System Carburetors: Dual Mikuni TM34 flat-slide carburetors Ignition: Digital CDI (Capacitor Discharge Ignition) with performance ignition curves Cooling System: Liquid-cooled with fan assistance Premix Oil: Requires a specific ratio of 2-stroke oil mixed with fuel or a separate oil injection system. 🔧 Transmission Standard Transmission Type: 6-speed constant mesh sequential gearbox Clutch Type: Wet, multi-plate, cable-operated Features Gear Ratios: Specific gear ratios are detailed within the manual, crucial for performance tuning. Final Drive: Chain drive 📐 Dimensions Exterior Length: Approximately 2000 mm Width: Approximately 720 mm Height: Approximately 1140 mm Wheelbase: Approximately 1390 mm Weights Dry Weight: Approximately 135-140 kg Fuel Tank Capacity: Approximately 16 liters 🛡️ Safety Features Ratings Safety Ratings: Motorcycles are not rated by traditional automotive safety organizations like NHTSA or IIHS. Safety is primarily dependent on rider skill and adherence to safe riding practices. Active Features Active Features: Agile handling, responsive braking, powerful engine for acceleration. Rider aids are minimal, reflecting the performance-oriented nature of the bike. Passive Features Passive Features: Sturdy frame, protective fairings, adequate lighting. Relies heavily on rider input and protective gear. 💡 Technology Features Infotainment Infotainment: As a 1998 sportbike, infotainment systems are non-existent. The focus is purely on mechanical performance and rider feedback. Driver Assistance Driver Assistance: No electronic rider aids like ABS or traction control were standard on this model. Connectivity Connectivity: No connectivity features. 🔧 Maintenance Service Intervals Oil Change Interval: Refer to manual for specific intervals, typically every 3,000-5,000 km for engine oil. Chain Maintenance: Regular cleaning, lubrication, and tension adjustment, typically every 500-1000 km. Brake Fluid Flush: Recommended every 2 years or as per manual to maintain braking performance. Fluid Specifications Engine Oil Type: High-quality 2-stroke synthetic or semi-synthetic engine oil (specific API/JASO ratings and viscosity grade provided in manual). Transmission Oil Type: Specific gear oil or transmission fluid (e.g., SAE 80W-90) as per manual. Capacity: Approx. 0.75 Liters. Coolant Type: Ethylene glycol based antifreeze/coolant mixture (50/50 ratio recommended). Brake Fluid Type: DOT 4 brake fluid is typically specified. Known Issues Known Issues: Potential for reed valve wear, exhaust power valve issues, carburetor synchronization challenges, and general wear and tear on high-performance two-stroke components. Performance Tuning: The manual will be critical for owners interested in performance tuning, jetting changes, and understanding the intricacies of the two-stroke power band. 📚 Vehicle History Brand Heritage Brand Heritage: Aprilia, an Italian manufacturer, has a...
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Type: Motorcycle
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Sku: 545683
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1998 APRILIA RS250 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
RS250
Year:
1998
Codes
Engine Code:
Rotax 2-stroke V-twin
👋 Introduction
Market Position
Market Position:
The Aprilia RS250 was positioned as a high-performance, track-inspired supersport motorcycle, competing with other 250cc two-stroke performance machines of its era.
Competitive Analysis
Competitors:
Key competitors included models like the Yamaha YZF-R25, Kawasaki Ninja ZX-25R (later models), and Suzuki RGV250.
Key Features
Key Features:
Lightweight chassis, potent V-twin two-stroke engine, advanced suspension, and aggressive styling.
Target Audience:
Enthusiasts and riders seeking a thrilling, agile, and track-capable motorcycle.
📋 Manual Details
Coverage Areas
Manual Type:
Complete Service and Repair Manual
Language:
English
Format:
Likely digital (PDF) or printed bound manual
Page Count:
Comprehensive (typically 300-500 pages for a full service manual)
📖 Manual Coverage
Systems Covered
Engine:
Top-end rebuild, bottom-end assembly, cooling system, lubrication, fuel delivery, ignition, exhaust
Transmission:
Clutch operation, gear selection, gearbox disassembly and assembly, lubrication
Chassis:
Frame inspection, suspension (front forks, rear shock), steering system, wheel bearings, swingarm
Brakes:
Front and rear brake system maintenance, hydraulic components, pad replacement, bleeding procedures
Electrical:
Wiring diagrams, lighting, ignition system, charging system, battery, starter motor, diagnostic troubleshooting
Fuel System:
Carburetor tuning and overhaul (Mikuni T-series), fuel tank, fuel lines, fuel pump (if applicable)
Procedures Included
Maintenance:
Regular scheduled maintenance, oil changes, filter replacements, chain adjustment, spark plug service
Troubleshooting:
Diagnostic flowcharts for common problems, electrical troubleshooting guides, performance issues
Repair:
Detailed step-by-step instructions for component disassembly, repair, and reassembly
Technical Specifications:
Torque specifications, clearances, fluid capacities, electrical resistance values
Technical Depth
Depth:
Comprehensive, covering from basic user maintenance to in-depth engine and transmission overhauls, suitable for professional technicians and advanced home mechanics
📊 Manual Specifications
File Format
File Format:
Likely PDF with searchable text for digital versions, high-quality print for physical copies
Print Quality
Print Quality:
High-resolution images and clear diagrams
Binding Type
Binding Type:
Professional binding (e.g., perfect binding, spiral binding) for longevity and ease of use in a workshop environment
Paper Type
Paper Type:
Durable, potentially glossy paper to withstand workshop conditions and protect against oil and grime.
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, 90-degree V-twin, two-stroke
Displacement:
249.3 cc (250cc class)
Bore X Stroke:
54.0 mm x 54.5 mm
Power Delivery:
Known for strong mid-range and top-end power delivery, characteristic of performance two-strokes.
Performance
Horsepower:
Approximately 70-75 HP (varies by region and specific tuning, often stated in the 70s HP range for homologation specials)
Torque:
Approximately 40-45 Nm (Newton-meters)
Fuel System
Carburetors:
Dual Mikuni TM34 flat-slide carburetors
Ignition:
Digital CDI (Capacitor Discharge Ignition) with performance ignition curves
Cooling System:
Liquid-cooled with fan assistance
Premix Oil:
Requires a specific ratio of 2-stroke oil mixed with fuel or a separate oil injection system.
🔧 Transmission
Standard
Transmission Type:
6-speed constant mesh sequential gearbox
Clutch Type:
Wet, multi-plate, cable-operated
Features
Gear Ratios:
Specific gear ratios are detailed within the manual, crucial for performance tuning.
Final Drive:
Chain drive
📐 Dimensions
Exterior
Length:
Approximately 2000 mm
Width:
Approximately 720 mm
Height:
Approximately 1140 mm
Wheelbase:
Approximately 1390 mm
Weights
Dry Weight:
Approximately 135-140 kg
Fuel Tank Capacity:
Approximately 16 liters
🛡️ Safety Features
Ratings
Safety Ratings:
Motorcycles are not rated by traditional automotive safety organizations like NHTSA or IIHS. Safety is primarily dependent on rider skill and adherence to safe riding practices.
Active Features
Active Features:
Agile handling, responsive braking, powerful engine for acceleration. Rider aids are minimal, reflecting the performance-oriented nature of the bike.
Passive Features
Passive Features:
Sturdy frame, protective fairings, adequate lighting. Relies heavily on rider input and protective gear.
💡 Technology Features
Infotainment
Infotainment:
As a 1998 sportbike, infotainment systems are non-existent. The focus is purely on mechanical performance and rider feedback.
Driver Assistance
Driver Assistance:
No electronic rider aids like ABS or traction control were standard on this model.
Connectivity
Connectivity:
No connectivity features.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Refer to manual for specific intervals, typically every 3,000-5,000 km for engine oil.
Chain Maintenance:
Regular cleaning, lubrication, and tension adjustment, typically every 500-1000 km.
Brake Fluid Flush:
Recommended every 2 years or as per manual to maintain braking performance.
Fluid Specifications
Engine Oil Type:
High-quality 2-stroke synthetic or semi-synthetic engine oil (specific API/JASO ratings and viscosity grade provided in manual).
Transmission Oil Type:
Specific gear oil or transmission fluid (e.g., SAE 80W-90) as per manual. Capacity: Approx. 0.75 Liters.
Coolant Type:
Ethylene glycol based antifreeze/coolant mixture (50/50 ratio recommended).
Brake Fluid Type:
DOT 4 brake fluid is typically specified.
Known Issues
Known Issues:
Potential for reed valve wear, exhaust power valve issues, carburetor synchronization challenges, and general wear and tear on high-performance two-stroke components.
Performance Tuning:
The manual will be critical for owners interested in performance tuning, jetting changes, and understanding the intricacies of the two-stroke power band.
📚 Vehicle History
Brand Heritage
Brand Heritage:
Aprilia, an Italian manufacturer, has a strong heritage in motorcycle racing, particularly in Grand Prix classes with two-stroke engines.
Model Evolution
Model Evolution:
The RS250 evolved from Aprilia's racing success and incorporated technology from Suzuki's RGV250 platform, leveraging shared components and engineering expertise.
Production
Production Years:
Approximately 1994-2003
Manufacturing Origin:
Italy
🏆 Awards & Recognition
Recognitions
Recognitions:
The RS250 was widely praised in contemporary motorcycle reviews for its sharp handling, strong performance, and racing pedigree. It is considered a classic in the 250cc two-stroke supersport category.
Ratings
Performance Ratings:
Consistently rated highly for its track performance and agility by motorcycle journalists of its era.
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