🏷️ Basic Information Identification Make: Aprilia Model: RS250 Year: 1998 Vehicle Type: Motorcycle Product Name: Aprilia RS250 1998 Motorcycle Service Repair Manual 👋 Introduction Market Position Segment: Lightweight supersport motorcycle, popular for its track-day performance and aggressive styling. Target Audience: Performance-oriented riders, track day enthusiasts, and DIY mechanics. Competitive Analysis Key Competitors: Yamaha RZ350, Suzuki RGV250, Honda NSR250. Key Features Engine Type: V-twin, two-stroke engine derived from Suzuki RG V-gamma technology. Performance Characteristics: Lightweight chassis, sharp handling, potent acceleration, and exhilarating two-stroke power delivery. Design Inspiration: Based on the championship-winning Suzuki RGV250 racing motorcycles. 📋 Manual Details Coverage Areas Manual Type: Service Repair Manual Language: English Format: ZIP Download Compatible Os: Windows Manual Specifications File Format: Digital (ZIP archive, likely containing PDF files) Print Quality: Assumed to be high-quality digital reproduction, suitable for printing if desired. Binding Type: N/A (Digital download) Paper Type: N/A (Digital download) 📖 Manual Coverage Systems Covered Engine: Detailed breakdown, tuning, and diagnostics for the 2-stroke V-twin engine. Cooling System: Radiator, hoses, thermostat, coolant specifications and bleeding procedures. Fuel System: Carburetor (Dell'Orto PHBH 28) disassembly, cleaning, adjustment, jetting, fuel pump operation, and fuel tank maintenance. Ignition System: CDI ignition, spark plug specifications, timing adjustments, and component testing. Exhaust System: Expansion chambers, silencer removal and reinstallation, and exhaust port cleaning. Transmission: Gearbox disassembly, inspection, repair, clutch assembly, cable adjustment, and oil specifications. Clutch: Wet multi-plate clutch, operation, adjustment, replacement of friction plates, and pressure springs. Chassis Frame: Frame inspection, alignment checks, and structural integrity. Suspension Front: Upside-down telescopic fork (Showa), disassembly, inspection, oil replacement, seal replacement, spring preload adjustment. Suspension Rear: Monoshock absorber (Monoflex), linkage system, adjustment of damping and preload, bearing inspection. Brakes Front: Dual disc brakes, caliper overhaul, pad replacement, master cylinder service, fluid flush and bleeding, disc specifications. Brakes Rear: Single disc brake, caliper overhaul, pad replacement, master cylinder service, fluid flush and bleeding. Wheels Tires: Wheel bearing inspection and replacement, tire pressure recommendations, wheel balancing. Electrical System: Wiring diagrams, lighting system, charging system (stator, rectifier/regulator), battery maintenance, starter motor, horn, switchgear. Bodywork: Fairing removal and installation, seat, fuel tank, fenders, and minor cosmetic repairs. Instruments Controls: Dashboard instrumentation, throttle, clutch lever, brake lever adjustments, and control cable routing. Procedures Included Routine Maintenance: Oil changes, filter replacements, chain adjustment, lubrication points, general inspection. Troubleshooting: Diagnostic flowcharts and common problem identification for engine, electrical, and mechanical issues. Major Overhauls: Engine rebuild procedures, transmission overhaul, carburetor synchronization. Component Replacement: Detailed steps for replacing wear items and major components across all systems. Adjustments: Carburetor tuning, suspension settings, clutch and brake lever adjustments, idle speed. Technical Depth Diagnostic Capabilities: Advanced diagnostic procedures, fault finding using specific symptoms and expected outcomes. Repair Complexity: Covers everything from basic bolt-on parts replacement to complete engine and transmission rebuilds. Special Tools: Lists and explains the use of any specialized tools required for specific procedures. Torque Specifications: Precise torque values for critical fasteners across all major components. ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 49.9-degree V-twin, two-stroke Bore X Stroke: 54.0 mm x 54.5 mm Displacement: 249 cc Compression Ratio: 7.3:1 (or similar, check manual for exact) Valvetrain: Reed valve intake, power jet carburetors, electronically controlled exhaust power valves (SAEC - Suzuki Advanced Exhaust Control). Performance Horsepower: Approx. 70 HP at 11,000 RPM (at crank) Torque: Approx. 32 lb-ft (43 Nm) at 10,000 RPM Fuel System Carburetors: 2 x Dell'Orto PHBH 28 AS/BS Fuel Type: Unleaded gasoline (95 RON or higher recommended), requires 2-stroke oil premix or auto-lube system. Oil System: Automatic oil injection (separate oil tank) or pre-mix required for two-stroke lubrication. 🔧 Transmission Standard Transmission Type: 6-speed constant mesh Optional Quickshifter: N/A (Aftermarket options may exist) Features Clutch Type: Wet multi-plate Final Drive: 525 O-ring chain 📐 Dimensions Exterior Length: Approx. 2010 mm (79.1 in) Width: Approx. 720 mm (28.3 in) Height: Approx. 1135 mm (44.7 in) Wheelbase: Approx. 1370 mm (53.9 in) Ground Clearance: Approx. 130 mm (5.1 in) Weights Dry Weight: Approx. 141 kg (310.8 lbs) Wet Weight: Approx. 164 kg (361.5 lbs) Fuel Tank Capacity: 16 Liters (4.2 US gallons) 🛡️ Safety Features Ratings Crash Test Results: N/A (Motorcycles are not typically rated by consumer safety organizations like NHTSA or Euro NCAP). Active Features Braking System: High-performance dual front discs with four-piston calipers, single rear disc. Tire Technology: Sport-oriented tire fitment recommended for optimal grip. Passive Features Frame Design: Aluminum twin-spar frame designed for rigidity and responsive handling. Ergonomics: Aggressive, forward-leaning riding position for performance riding. 💡 Technology Features Infotainment Display Type: Analog tachometer and speedometer, basic warning lights. No digital infotainment system. Driver Assistance Electronic Aids: None. The RS250 is a pure mechanical machine with no electronic rider aids (e.g., ABS, traction control). 🔧 Maintenance Service Intervals Engine Oil Change: Refer to manual, typically every 3,000-5,000 km (1,800-3,000 miles) or annually. Spark Plug Replacement: Refer to...