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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, 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: PDF 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) Instrumentation Dashboard Layout: Analogue speedometer, tachometer, coolant temperature gauge, indicator lights. Lighting Headlight...
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Sku: 549484
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1998 Aprilia RS250 Factory Service Repair Manual
🏷️ 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:
PDF
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)
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.
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