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Aprilia RS250 1997 Full Service Repair Manual

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$133.00
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🏷️ Basic Information Identification Make: Aprilia Model: RS250 Year: 1997 Generation Model Generation: MK1 👋 Introduction Market Position Segment: Lightweight Sportbike Reputation: Highly regarded for its performance, handling, and aggressive styling, often considered a homologation special. Competitive Analysis Key Competitors: Yamaha YZF-R6, Honda CBR600F, Kawasaki ZX-6R, Suzuki GSX-R600. Key Features Engine Type: Liquid-cooled, 70-degree V-twin, two-stroke. Frame: Aluminum twin-spar frame. Suspension: High-quality adjustable front and rear suspension. Brakes: Potent Brembo braking system. Design: Aerodynamic fairings inspired by Aprilia's racing heritage. 📋 Manual Details Coverage Areas Primary Coverage: Full Service Repair Additional Coverage: Maintenance, Rebuilding, Refurbishment, Restoration Page Count Estimated Pages: Highly Detailed (specific page count not provided, but described as comprehensive) Manual Type Type: Service and Repair Manual Language Language: Likely English (standard for international service manuals, but not explicitly stated) Format Format: Digital (implied by product description for online sale) 📖 Manual Coverage Systems Covered Engine: Comprehensive engine diagnostics, overhaul, tuning, lubrication, cooling, and fuel systems. Transmission: Clutch, gearbox, shift mechanisms, and associated components. Chassis And Suspension: Frame, front fork (Sachs/Showa based on typical RS250), rear shock absorber (Ohlins or Sachs), swingarm, steering system, and wheel bearings. Brakes: Front and rear brake systems, including master cylinders, calipers (typically Brembo), lines, and fluid replacement. Electrical System: Ignition system (CDI), lighting, charging system, wiring diagrams, sensors, and battery management. Fuel System: Carburetor tuning (likely Dell'Orto PHBH 28 or similar), fuel lines, and fuel pump operation. Exhaust System: Expansion chambers, silencer maintenance, and leak detection. Cooling System: Radiator, coolant hoses, water pump, and thermostat operation for the liquid-cooled engine. Bodywork And Fairings: Panel removal and installation, decal placement, and cosmetic repairs. Procedures Included Maintenance: Regular servicing, oil changes, filter replacements, chain adjustment, brake bleeding, and spark plug replacement. Troubleshooting: Diagnosis of common problems, electrical gremlins, engine performance issues, and starting difficulties. Repair: Detailed step-by-step instructions for component repair and replacement across all major systems. Rebuilding And Restoration: Engine rebuild procedures, carburetor overhauls, suspension component refurbishment, and chassis restoration guidance. Tuning And Adjustment: Carburetor jetting, ignition timing adjustments, and suspension setup recommendations. Technical Depth Depth: Comprehensive from basic rider maintenance to complete engine teardown and rebuild. Diagnostic Capabilities: Detailed diagnostic procedures and specifications for identifying and rectifying faults. 📊 Manual Specifications File Format Digital Format: PDF (Portable Document Format) is the most common and expected format for digital service manuals. Print Quality Image Resolution: High-resolution images and diagrams are expected for clarity in repair procedures. Binding Type Binding: N/A (Digital Format) Paper Type Paper Quality: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 70° V-twin, two-stroke, reed valve induction. Displacement: 249.2 cc (15.2 cubic inches) Bore X Stroke: 54.0 mm x 54.4 mm (2.13 in x 2.14 in) Compression Ratio: Approximately 7.0:1 (varies slightly by market/tuning) Power Output: Approx. 70 HP (52 kW) @ 11,000 RPM (claimed) Torque: Approx. 28 lb-ft (38 Nm) @ 10,500 RPM (claimed) Fuel System Carburetors: Twin Dell'Orto PHBH 28 or Mikuni TMX30 (depending on market and revision) Fuel Type: Unleaded gasoline, minimum 95 RON (equivalent to 91 AKI), with 2-stroke oil mixture (automatic oil injection). Oil Injection: Automatic oil injection system with separate reservoir. Lubrication Engine Oil Type: High-quality 2-stroke synthetic or semi-synthetic oil. Cooling System Coolant Type: Ethylene glycol based coolant (50/50 mix with distilled water). 🔧 Transmission Standard Type: 6-speed sequential manual transmission. Features Clutch: Wet multi-plate clutch, hydraulically operated. Final Drive: Chain drive. 📐 Dimensions Exterior Length: Approx. 2000 mm (78.7 in) Width: Approx. 710 mm (28.0 in) Height: Approx. 1140 mm (44.9 in) Wheelbase: Approx. 1370 mm (53.9 in) Weights Dry Weight: Approx. 140 kg (308.6 lbs) Wet Weight: Approx. 158 kg (348.3 lbs) (with fluids) 🛡️ Safety Features Ratings Safety Certification: Meets European and North American safety standards of its era. Active Features Braking System: Dual front disc brakes (e.g., 320mm discs with Brembo calipers) and single rear disc brake (e.g., 220mm disc with Brembo caliper). Tire Sizes: Front: 120/70-17, Rear: 160/60-17 (typical fitment) Passive Features Lighting: Dual halogen headlights, LED taillight. 💡 Technology Features Infotainment Infotainment System: N/A (No integrated infotainment system; focus is on performance and rider experience). Driver Assistance Rider Assistance: N/A (No electronic rider aids like ABS or traction control). Engine Management Ignition System: CDI (Capacitor Discharge Ignition) with electronic power valve control. Suspension Technology Front Suspension Type: Inverted telescopic forks (e.g., Sachs or Showa) with adjustable preload, compression, and rebound damping. Rear Suspension Type: Monoshock with linkage, featuring adjustable preload, compression, and rebound damping (often Öhlins or Sachs). 🔧 Maintenance Service Intervals Oil Change Engine: Check level frequently, top up as needed. Complete oil change typically at rebuild or significant mileage intervals. Spark Plugs: Check and clean/replace every 3,000-5,000 km (1,800-3,000 miles) or as per manual. NGK BR9EG or BR9ES often recommended. Air Filter: Inspect and clean/replace every 6,000-8,000 km (3,700-5,000 miles). Chain Maintenance: Clean,...
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Sku: 417301
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Aprilia RS250 1997 Full Service Repair Manual
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
RS250
Year:
1997
Generation
Model Generation:
MK1
👋 Introduction
Market Position
Segment:
Lightweight Sportbike
Reputation:
Highly regarded for its performance, handling, and aggressive styling, often considered a homologation special.
Competitive Analysis
Key Competitors:
Yamaha YZF-R6, Honda CBR600F, Kawasaki ZX-6R, Suzuki GSX-R600.
Key Features
Engine Type:
Liquid-cooled, 70-degree V-twin, two-stroke.
Frame:
Aluminum twin-spar frame.
Suspension:
High-quality adjustable front and rear suspension.
Brakes:
Potent Brembo braking system.
Design:
Aerodynamic fairings inspired by Aprilia's racing heritage.
📋 Manual Details
Coverage Areas
Primary Coverage:
Full Service Repair
Additional Coverage:
Maintenance, Rebuilding, Refurbishment, Restoration
Page Count
Estimated Pages:
Highly Detailed (specific page count not provided, but described as comprehensive)
Manual Type
Type:
Service and Repair Manual
Language
Language:
Likely English (standard for international service manuals, but not explicitly stated)
Format
Format:
Digital (implied by product description for online sale)
📖 Manual Coverage
Systems Covered
Engine:
Comprehensive engine diagnostics, overhaul, tuning, lubrication, cooling, and fuel systems.
Transmission:
Clutch, gearbox, shift mechanisms, and associated components.
Chassis And Suspension:
Frame, front fork (Sachs/Showa based on typical RS250), rear shock absorber (Ohlins or Sachs), swingarm, steering system, and wheel bearings.
Brakes:
Front and rear brake systems, including master cylinders, calipers (typically Brembo), lines, and fluid replacement.
Electrical System:
Ignition system (CDI), lighting, charging system, wiring diagrams, sensors, and battery management.
Fuel System:
Carburetor tuning (likely Dell'Orto PHBH 28 or similar), fuel lines, and fuel pump operation.
Exhaust System:
Expansion chambers, silencer maintenance, and leak detection.
Cooling System:
Radiator, coolant hoses, water pump, and thermostat operation for the liquid-cooled engine.
Bodywork And Fairings:
Panel removal and installation, decal placement, and cosmetic repairs.
Procedures Included
Maintenance:
Regular servicing, oil changes, filter replacements, chain adjustment, brake bleeding, and spark plug replacement.
Troubleshooting:
Diagnosis of common problems, electrical gremlins, engine performance issues, and starting difficulties.
Repair:
Detailed step-by-step instructions for component repair and replacement across all major systems.
Rebuilding And Restoration:
Engine rebuild procedures, carburetor overhauls, suspension component refurbishment, and chassis restoration guidance.
Tuning And Adjustment:
Carburetor jetting, ignition timing adjustments, and suspension setup recommendations.
Technical Depth
Depth:
Comprehensive from basic rider maintenance to complete engine teardown and rebuild.
Diagnostic Capabilities:
Detailed diagnostic procedures and specifications for identifying and rectifying faults.
📊 Manual Specifications
File Format
Digital Format:
PDF (Portable Document Format) is the most common and expected format for digital service manuals.
Print Quality
Image Resolution:
High-resolution images and diagrams are expected for clarity in repair procedures.
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper Quality:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, 70° V-twin, two-stroke, reed valve induction.
Displacement:
249.2 cc (15.2 cubic inches)
Bore X Stroke:
54.0 mm x 54.4 mm (2.13 in x 2.14 in)
Compression Ratio:
Approximately 7.0:1 (varies slightly by market/tuning)
Power Output:
Approx. 70 HP (52 kW) @ 11,000 RPM (claimed)
Torque:
Approx. 28 lb-ft (38 Nm) @ 10,500 RPM (claimed)
Fuel System
Carburetors:
Twin Dell'Orto PHBH 28 or Mikuni TMX30 (depending on market and revision)
Fuel Type:
Unleaded gasoline, minimum 95 RON (equivalent to 91 AKI), with 2-stroke oil mixture (automatic oil injection).
Oil Injection:
Automatic oil injection system with separate reservoir.
Lubrication
Engine Oil Type:
High-quality 2-stroke synthetic or semi-synthetic oil.
Cooling System
Coolant Type:
Ethylene glycol based coolant (50/50 mix with distilled water).
🔧 Transmission
Standard
Type:
6-speed sequential manual transmission.
Features
Clutch:
Wet multi-plate clutch, hydraulically operated.
Final Drive:
Chain drive.
📐 Dimensions
Exterior
Length:
Approx. 2000 mm (78.7 in)
Width:
Approx. 710 mm (28.0 in)
Height:
Approx. 1140 mm (44.9 in)
Wheelbase:
Approx. 1370 mm (53.9 in)
Weights
Dry Weight:
Approx. 140 kg (308.6 lbs)
Wet Weight:
Approx. 158 kg (348.3 lbs) (with fluids)
🛡️ Safety Features
Ratings
Safety Certification:
Meets European and North American safety standards of its era.
Active Features
Braking System:
Dual front disc brakes (e.g., 320mm discs with Brembo calipers) and single rear disc brake (e.g., 220mm disc with Brembo caliper).
Tire Sizes:
Front: 120/70-17, Rear: 160/60-17 (typical fitment)
Passive Features
Lighting:
Dual halogen headlights, LED taillight.
💡 Technology Features
Infotainment
Infotainment System:
N/A (No integrated infotainment system; focus is on performance and rider experience).
Driver Assistance
Rider Assistance:
N/A (No electronic rider aids like ABS or traction control).
Engine Management
Ignition System:
CDI (Capacitor Discharge Ignition) with electronic power valve control.
Suspension Technology
Front Suspension Type:
Inverted telescopic forks (e.g., Sachs or Showa) with adjustable preload, compression, and rebound damping.
Rear Suspension Type:
Monoshock with linkage, featuring adjustable preload, compression, and rebound damping (often Öhlins or Sachs).
🔧 Maintenance
Service Intervals
Oil Change Engine:
Check level frequently, top up as needed. Complete oil change typically at rebuild or significant mileage intervals.
Spark Plugs:
Check and clean/replace every 3,000-5,000 km (1,800-3,000 miles) or as per manual. NGK BR9EG or BR9ES often recommended.
Air Filter:
Inspect and clean/replace every 6,000-8,000 km (3,700-5,000 miles).
Chain Maintenance:
Clean, lubricate, and adjust chain tension every 500-1,000 km (300-600 miles).
Brake Fluid:
Replace brake fluid annually (DOT 4 recommended).
Fluid Specifications
Engine Oil:
High-quality 2-stroke synthetic oil (e.g., Motul 710 2T, Castrol TTS).
Coolant:
50/50 mix of ethylene glycol based antifreeze and distilled water.
Brake Fluid:
DOT 4
Transmission Oil:
Gear oil, typically SAE 75W-90 or 80W-90 API GL-4. Capacity: Approx. 0.7 Liters.
Known Issues
Power Valves:
Sticking or malfunctioning power valves due to carbon buildup is common; requires regular cleaning and maintenance.
Carburetor Tuning:
Can be sensitive to altitude and temperature changes, requiring periodic jetting adjustments for optimal performance.
Electrical Gremlins:
Older wiring harnesses can develop corrosion or breakages, leading to intermittent electrical issues.
Clutch Wear:
Clutch plates can wear over time, especially under aggressive use, requiring replacement.
Radiator Leaks:
Aging rubber hoses or radiators can develop leaks; regular inspection is advised.
📚 Vehicle History
Brand Heritage
Brand Origin:
Aprilia is an Italian manufacturer with a strong heritage in Grand Prix motorcycle racing, particularly in the 125cc and 250cc classes.
Model Evolution
Rs250 Development:
Developed from the highly successful Suzuki RGV250 Gamma donor engine and chassis components, with Aprilia engineering and styling.
Production
Production Period:
Produced from 1995 to 2003, with the 1997 model being part of the first generation (MK1).
Manufacturing Location:
Italy
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