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Aprilia RS 250 1995 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Aprilia Model: RS 250 Year: 1995 Product Type: Factory Service Repair Manual 👋 Introduction Market Position Segment: High-performance sportbike, 250cc class Target Audience: Enthusiast owners and independent mechanics seeking detailed repair and maintenance information. Competitive Analysis Competitors 1995: Honda CBR250RR, Kawasaki ZXR250, Suzuki RGV250 Gamma Key Features Manual Value Proposition: Provides OEM-level technical data and repair procedures, empowering users to perform maintenance and repairs effectively, saving time and money. Ease Of Use: Described as 'very simple to use' with clear instructions and diagrams. 📋 Manual Details Coverage Areas General Information: True Periodic Maintenance: True Tune Up Procedures: True Engine: True Fuel And Lubrication System: True Cooling System: True Electrical System: True Chassis: True Servicing Information: True Updates: True Page Count Estimated Pages: Detailed page count not specified, but described as 'COMPLETE' and 'packed with all the information you need'. Manual Type Type: Factory Service Repair Manual Language Language: English (Implied by description and typical manual conventions) Format File Format: PDF Software Requirements: Adobe PDF Reader, WinZip Compatibility: All Versions of Windows & Mac Zoom Functionality: Yes 📖 Manual Coverage Systems Covered Engine Overview: Comprehensive coverage including engine disassembly, assembly, and internal component details. Fuel System: Detailed information on fuel delivery, carburetor settings (likely Mikuni VM26SS as standard), fuel pump, and fuel lines. Lubrication System: Coverage of the automatic oil injection system, oil pump, oil tank, and lubrication points. Cooling System: Detailed procedures for radiator, water pump, thermostat, coolant flow, and troubleshooting leaks. Electrical System: Extensive coverage including wiring diagrams, ignition system, lighting, charging system (stator, rectifier/regulator), battery, and starter motor. Chassis Components: Coverage of frame, swingarm, suspension (front forks and rear shock), steering system, and wheels. Brakes: Detailed information on front and rear brake systems, including hydraulic components, pad replacement, bleeding procedures, and master cylinder/caliper servicing. Exhaust System: Information related to the exhaust manifold, pipes, and silencing components, with potential guidance on removal and installation. Procedures Included Basic Maintenance: Includes procedures for oil changes, filter replacements, spark plug changes, chain adjustment, and general inspections. Tune Up: Detailed steps for engine tuning, carburetor synchronization and adjustment, idle speed settings, and ignition timing checks. Troubleshooting: Diagnostic procedures and potential solutions for common problems across all major systems. Engine Rebuild: Step-by-step instructions for engine disassembly, internal component inspection, repair, and reassembly. Suspension Servicing: Fork oil changes, seal replacement, and rear shock absorber servicing information. Electrical Diagnostics: Guidance on diagnosing electrical faults using wiring diagrams and testing procedures. Torque Specifications: Specific torque values for critical fasteners across the motorcycle. Fluid Capacities: Required capacities for engine oil, coolant, brake fluid, and fork oil. Technical Depth Depth: Comprehensive, covering all workshop procedures from basic maintenance to complete engine and chassis overhauls. Equivalent to official dealer workshop manuals. Diagrams: Includes step-by-step diagrams for visual guidance on repair procedures. 📊 Manual Specifications File Format Digital Format: PDF Searchable: Likely searchable due to PDF format, aiding quick access to information. Print Quality Printability: Designed to be printable for workshop use. Binding Type Binding: N/A (Digital PDF format) Paper Type Paper Quality: N/A (Digital PDF format) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 2-stroke, V-twin (Suzuki RG250 Gamma derived) Displacement: 249 cc Bore X Stroke: 54.0 mm x 54.5 mm Compression Ratio: 7.1:1 (approximate, can vary by market/spec) Power Output: Approx. 70 hp @ 11,000 rpm (official figures often lower for street models, around 50-60 hp; the manual covers actual workshop specs) Torque: Approx. 39 Nm (28.7 lb-ft) @ 10,500 rpm (approximate) Fuel System Carburetors: Dual Mikuni VM26SS Fuel Type: Unleaded gasoline (95 RON or higher recommended) Oil Injection: Automatic 2-stroke oil injection system Lubrication Engine Oil Type: Specific 2-stroke motorcycle oil (refer to manual for exact API/JASO specifications, e.g., JASO FD) 🔧 Transmission Standard Transmission Type: 6-speed, constant mesh, return pattern Clutch: Wet, multi-plate Features Gear Ratios: Detailed gear ratios provided within the manual for each gear. Final Drive: Chain drive 📐 Dimensions Exterior Length: Approx. 2015 mm (79.3 in) Width: Approx. 710 mm (28.0 in) Height: Approx. 1135 mm (44.7 in) Wheelbase: Approx. 1365 mm (53.7 in) Weights Dry Weight: Approx. 130 kg (286.6 lbs) Fuel Tank Capacity: 16 Liters (4.2 US gal) 🛡️ Safety Features Active Features Braking System: Dual front disc brakes with hydraulic actuation, single rear disc brake with hydraulic actuation. Suspension: Upside-down telescopic front forks, link-type rear monoshock suspension for enhanced stability and handling. Passive Features Frame Construction: Aluminum twin-spar frame for rigidity and light weight. 💡 Technology Features Infotainment Features: Not applicable for this era of sportbike; focus is on mechanical and electrical systems. 🔧 Maintenance Service Intervals Oil Change Interval: Refer to manual for specific mileage/time intervals. Typically every 3,000-5,000 km or annually. Spark Plug Replacement: Refer to manual for specific intervals. Common for 2-strokes to require more frequent replacement. Coolant Flush: Refer to manual for...
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Tipo: Motorcycle
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Sku: 358077
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Aprilia RS 250 1995 Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
RS 250
Year:
1995
Product Type:
Factory Service Repair Manual
👋 Introduction
Market Position
Segment:
High-performance sportbike, 250cc class
Target Audience:
Enthusiast owners and independent mechanics seeking detailed repair and maintenance information.
Competitive Analysis
Competitors 1995:
Honda CBR250RR, Kawasaki ZXR250, Suzuki RGV250 Gamma
Key Features
Manual Value Proposition:
Provides OEM-level technical data and repair procedures, empowering users to perform maintenance and repairs effectively, saving time and money.
Ease Of Use:
Described as 'very simple to use' with clear instructions and diagrams.
📋 Manual Details
Coverage Areas
General Information:
True
Periodic Maintenance:
True
Tune Up Procedures:
True
Engine:
True
Fuel And Lubrication System:
True
Cooling System:
True
Electrical System:
True
Chassis:
True
Servicing Information:
True
Updates:
True
Page Count
Estimated Pages:
Detailed page count not specified, but described as 'COMPLETE' and 'packed with all the information you need'.
Manual Type
Type:
Factory Service Repair Manual
Language
Language:
English (Implied by description and typical manual conventions)
Format
File Format:
PDF
Software Requirements:
Adobe PDF Reader, WinZip
Compatibility:
All Versions of Windows & Mac
Zoom Functionality:
Yes
📖 Manual Coverage
Systems Covered
Engine Overview:
Comprehensive coverage including engine disassembly, assembly, and internal component details.
Fuel System:
Detailed information on fuel delivery, carburetor settings (likely Mikuni VM26SS as standard), fuel pump, and fuel lines.
Lubrication System:
Coverage of the automatic oil injection system, oil pump, oil tank, and lubrication points.
Cooling System:
Detailed procedures for radiator, water pump, thermostat, coolant flow, and troubleshooting leaks.
Electrical System:
Extensive coverage including wiring diagrams, ignition system, lighting, charging system (stator, rectifier/regulator), battery, and starter motor.
Chassis Components:
Coverage of frame, swingarm, suspension (front forks and rear shock), steering system, and wheels.
Brakes:
Detailed information on front and rear brake systems, including hydraulic components, pad replacement, bleeding procedures, and master cylinder/caliper servicing.
Exhaust System:
Information related to the exhaust manifold, pipes, and silencing components, with potential guidance on removal and installation.
Procedures Included
Basic Maintenance:
Includes procedures for oil changes, filter replacements, spark plug changes, chain adjustment, and general inspections.
Tune Up:
Detailed steps for engine tuning, carburetor synchronization and adjustment, idle speed settings, and ignition timing checks.
Troubleshooting:
Diagnostic procedures and potential solutions for common problems across all major systems.
Engine Rebuild:
Step-by-step instructions for engine disassembly, internal component inspection, repair, and reassembly.
Suspension Servicing:
Fork oil changes, seal replacement, and rear shock absorber servicing information.
Electrical Diagnostics:
Guidance on diagnosing electrical faults using wiring diagrams and testing procedures.
Torque Specifications:
Specific torque values for critical fasteners across the motorcycle.
Fluid Capacities:
Required capacities for engine oil, coolant, brake fluid, and fork oil.
Technical Depth
Depth:
Comprehensive, covering all workshop procedures from basic maintenance to complete engine and chassis overhauls. Equivalent to official dealer workshop manuals.
Diagrams:
Includes step-by-step diagrams for visual guidance on repair procedures.
📊 Manual Specifications
File Format
Digital Format:
PDF
Searchable:
Likely searchable due to PDF format, aiding quick access to information.
Print Quality
Printability:
Designed to be printable for workshop use.
Binding Type
Binding:
N/A (Digital PDF format)
Paper Type
Paper Quality:
N/A (Digital PDF format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, 2-stroke, V-twin (Suzuki RG250 Gamma derived)
Displacement:
249 cc
Bore X Stroke:
54.0 mm x 54.5 mm
Compression Ratio:
7.1:1 (approximate, can vary by market/spec)
Power Output:
Approx. 70 hp @ 11,000 rpm (official figures often lower for street models, around 50-60 hp; the manual covers actual workshop specs)
Torque:
Approx. 39 Nm (28.7 lb-ft) @ 10,500 rpm (approximate)
Fuel System
Carburetors:
Dual Mikuni VM26SS
Fuel Type:
Unleaded gasoline (95 RON or higher recommended)
Oil Injection:
Automatic 2-stroke oil injection system
Lubrication
Engine Oil Type:
Specific 2-stroke motorcycle oil (refer to manual for exact API/JASO specifications, e.g., JASO FD)
🔧 Transmission
Standard
Transmission Type:
6-speed, constant mesh, return pattern
Clutch:
Wet, multi-plate
Features
Gear Ratios:
Detailed gear ratios provided within the manual for each gear.
Final Drive:
Chain drive
📐 Dimensions
Exterior
Length:
Approx. 2015 mm (79.3 in)
Width:
Approx. 710 mm (28.0 in)
Height:
Approx. 1135 mm (44.7 in)
Wheelbase:
Approx. 1365 mm (53.7 in)
Weights
Dry Weight:
Approx. 130 kg (286.6 lbs)
Fuel Tank Capacity:
16 Liters (4.2 US gal)
🛡️ Safety Features
Active Features
Braking System:
Dual front disc brakes with hydraulic actuation, single rear disc brake with hydraulic actuation.
Suspension:
Upside-down telescopic front forks, link-type rear monoshock suspension for enhanced stability and handling.
Passive Features
Frame Construction:
Aluminum twin-spar frame for rigidity and light weight.
💡 Technology Features
Infotainment
Features:
Not applicable for this era of sportbike; focus is on mechanical and electrical systems.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Refer to manual for specific mileage/time intervals. Typically every 3,000-5,000 km or annually.
Spark Plug Replacement:
Refer to manual for specific intervals. Common for 2-strokes to require more frequent replacement.
Coolant Flush:
Refer to manual for specific intervals. Typically every 1-2 years.
Fluid Specifications
Engine Oil Grade:
Refer to manual for specific viscosity and API/JASO standards (e.g., SAE 10W-40, JASO FD recommended).
Coolant Type:
Ethylene glycol-based antifreeze coolant (refer to manual for specific mixture ratio and type).
Brake Fluid:
DOT 4 hydraulic brake fluid (refer to manual for exact specification).
Fork Oil Grade:
Refer to manual for recommended fork oil viscosity (e.g., SAE 10W).
Known Issues
Common Wear Items:
Piston rings, reed valves, clutch plates, fork seals, and crankshaft seals due to the high-strung nature of 2-stroke engines.
Electrical Gremlins:
Older wiring harnesses can degrade; checking connectors and grounds is crucial for electrical system reliability.
Carburetor Issues:
Carburetors may require periodic cleaning and synchronization due to their complexity and performance tuning.
📚 Vehicle History
Brand Heritage
Aprilia Legacy:
Aprilia has a strong racing heritage, particularly in the 125cc and 250cc Grand Prix classes, which heavily influenced the development of the RS 250.
Model Evolution
Rs 250 Development:
The RS 250 was developed by Aprilia using Suzuki's RGV250 V-twin engine and chassis components, with Aprilia contributing its own styling, suspension tuning, and electronics.
Production
Production Years:
1995-2003
Manufacturing Location:
Italy
🏆 Awards & Recognition
Recognitions
Market Reputation:
Highly regarded by enthusiasts for its performance, handling, and distinctive V-twin 2-stroke sound and power delivery. Often praised as one of the best handling bikes of its era.
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