Aprilia RS250 Service Repair Manual 1994 1998

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📚 Vehicle Manual Information Aprilia RS250 Service Repair Manual 1994 1998 📋 Jump to Section... 🏷️ Basic Information 👋 Introduction 📋 Manual Details 📖 Manual Coverage 📊 Manual Specifications ⚙️...

Tipo: Motorcycles

Fabricante:

Sku: 543872

Tag: Aprilia Misc

Variantes do produto

Description

📚 Vehicle Manual Information

Aprilia RS250 Service Repair Manual 1994 1998

🏷️ Basic Information

Identification

Make:

Aprilia

Model:

RS250

Product Name:

Aprilia RS250 Service Repair Manual 1994-1998

Codes

Engine Code Variant:

Rotax 250 V-Twin (derived from Suzuki RG250 Gamma)

Chassis Codes Variants:

RS250 MK1 (94-97), RS250 NIKY (98)

👋 Introduction

Market Position

Motorcycle Segment:

Lightweight two-stroke supersport

Target Audience:

Enthusiasts, track day riders, mechanics

Competitive Analysis

Key Competitors:

Yamaha YZF-R6, Honda CBR600F, Suzuki GSX-R600 (though RS250 is 2-stroke, it competed in the sporty 250-400cc class)

Key Features

Performance Focus:

High-revving two-stroke engine, sharp handling, racing heritage

Historical Significance:

Carried Aprilia's racing DNA into a production streetbike, built around a potent Rotax engine

📋 Manual Details

Coverage Areas

Coverage Years:

1994, 1995, 1996, 1997, 1998

Market Coverage:

Global (primarily European and North American specifications)

Page Count

Estimated Pages:

300-500 (estimated, specific page count not provided in product info)

Manual Type

Manual Type:

Service Repair Manual

Language

Language:

English (assumed, common for international service manuals)

Format

Format:

Electronic (PDF)

📖 Manual Coverage

Systems Covered

Engine:

2-stroke V-twin, cooling system, lubrication, ignition, fuel delivery (carburetors), exhaust system, top-end rebuild, bottom-end rebuild

Transmission:

6-speed gearbox, clutch operation and adjustment, gear selection mechanism, lubrication

Chassis:

Frame inspection and repair, steering head bearing service, swingarm and rear suspension linkage maintenance, wheel bearing replacement

Suspension:

Front fork overhaul (Öhlins USD forks on some variants), rear shock absorber service and adjustment, spring rate specifications

Brakes:

Front and rear brake system service, caliper overhaul, master cylinder rebuild, fluid replacement, bleeding procedures, disc and pad specifications

Electrical:

Wiring diagrams, lighting system, battery and charging system, starter motor, ignition system components, sensor identification and testing

Fuel System:

Carburetor tuning and synchronization (Mikuni TM34-1), fuel tank maintenance, petcock operation, fuel line inspection

Bodywork:

Fairing removal and installation, seat and tail section, fuel tank mounting, graphics and paint care

Procedures Included

Maintenance:

Routine servicing, oil changes, filter replacements, chain adjustment, spark plug replacement, air filter cleaning/replacement

Repair:

Engine rebuild, transmission overhaul, suspension component replacement, brake system repair, electrical diagnostics and component replacement

Troubleshooting:

Diagnostic flowcharts for common starting issues, running problems, electrical faults, and performance degradation

Tuning:

Carburetor jetting and adjustments for altitude and exhaust modifications, ignition timing adjustments (if applicable)

Technical Depth

Depth:

Comprehensive workshop level; covers basic maintenance to complete engine and chassis rebuilds

Illustrations:

High-quality diagrams and illustrations for all procedures

Format Detail:

Step-by-step instructions

📊 Manual Specifications

File Format

File Format:

PDF (Portable Document Format)

Searchability:

Likely text-searchable if properly OCR'd

Print Quality

Print Readability:

Optimized for digital viewing and printing

Binding Type

Binding Type:

N/A (Electronic Format)

Paper Type

Paper Type:

N/A (Electronic Format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Liquid-cooled, 2-stroke, 90-degree V-twin

Displacement:

249 cc

Bore X Stroke:

54 mm x 54.5 mm

Compression Ratio:

7.5:1 (typical for high-performance 2-strokes)

Power Output:

Approx. 70-72 HP (at crankshaft, depending on market and tuning)

Torque Output:

Approx. 40-42 Nm (at crankshaft)

Performance

Redline:

11,500 RPM (approx.)

Top Speed:

Approx. 220 km/h (137 mph)

Fuel System

Carburetors:

2 x Mikuni TM34-1 Flat Slide

Fuel Type:

Unleaded gasoline, minimum 95 RON (octane rating is crucial for 2-strokes)

Oil Injection:

Automatic oil injection system (separate reservoir)

Lubrication

Crankcase:

Wet sump (for gearbox and crank bearings)

Cooling System

Type:

Liquid-cooled

Coolant Type:

Ethylene glycol-based coolant (e.g., Motul Motocool Expert, Castrol Radicool)

Coolant Capacity:

Approx. 1.5 liters

Ignition

Type:

Digital CDI (Capacitor Discharge Ignition)

Spark Plugs:

NGK R7273-9 or equivalent (specific plug number vital)

🔧 Transmission

Standard

Type:

6-speed constant mesh

Gear Ratios:

1st: 2.833 (34/12), 2nd: 2.056 (37/18), 3rd: 1.619 (34/21), 4th: 1.333 (32/24), 5th: 1.154 (30/26), 6th: 1.000 (28/28)

Final Drive:

Chain drive (520 pitch)

Features

Clutch Type:

Wet multi-plate, cable-actuated

Transmission Oil Type:

API GL-4 SAE 75W/90 or 10W/40 motorcycle gear oil (check manual for precise specification)

Transmission Oil Capacity:

Approx. 0.8 - 1.0 liters

📐 Dimensions

Exterior

Length:

Approx. 1960 mm

Width:

Approx. 720 mm

Height:

Approx. 1135 mm

Wheelbase:

Approx. 1375 mm

Ground Clearance:

Approx. 130 mm

Weights

Dry Weight:

Approx. 140 kg

Wet Weight:

Approx. 155 kg (fully fueled)

Fuel Tank Capacity:

16 liters

Wheels Tires

Front Wheel:

17 x 3.50 inch alloy

Rear Wheel:

17 x 4.50 inch alloy

Front Tire Size:

120/70ZR17

Rear Tire Size:

160/60ZR17

Wheelbase Measurement Standard:

ISO 13884

🛡️ Safety Features

Ratings

Crash Test Ratings:

N/A (Motorcycle safety standards vary greatly from automobiles; focus is on rider protection via design and equipment)

Active Features

Braking System:

Dual front discs (320mm), single rear disc (240mm), dual-piston calipers (Brembo or equivalent)

Suspension Geometry:

Designed for stability and responsiveness

Passive Features

Lighting:

Halogen headlight, LED taillight

Chassis Design:

Lightweight aluminum twin-spar frame

💡 Technology Features

Infotainment

Infotainment System:

N/A (Focus is on performance and handling, not integrated electronics)

Driver Assistance

Driver Assistance Systems:

Connectivity

Connectivity Features:

Engine Management

Electronic Controls:

Digital CDI ignition, automatic oil injection.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 4,000-6,000 km or annually (check manual for specific recommendation)

Spark Plug Replacement:

Every 5,000-8,000 km (depending on usage and spark plug type)

Air Filter Cleaning:

Every 2,000-3,000 km

Chain Lubrication:

Every 500 km or after riding in wet conditions

Brake Fluid Flush:

Every 2 years

Fluid Specifications

Engine Oil Type:

High-quality 2-stroke synthetic or semi-synthetic motorcycle oil, specifically formulated for high-performance 2-strokes (e.g., Motul 800 2T, Castrol TTS).

Two Stroke Oil Ratio:

Automatic injection system, do not mix with fuel.

Brake Fluid Type:

DOT 4

Known Issues

Common Problems:

Carburetor synchronization drift, exhaust powervalve issues, starter motor wear, general 2-stroke maintenance requirements (proper warm-up, correct oil).

Powervalve Maintenance:

Carbon buildup in powervalves can affect performance and requires regular cleaning.

📚 Vehicle History

Brand Heritage

Manufacturer Origin:

Aprilia S.p.A., Italy

Racing Legacy:

Aprilia has a strong history in Grand Prix motorcycle racing, particularly in the 125cc and 250cc classes.

Model Evolution

Development Basis:

The RS250 was heavily based on the championship-winning Suzuki RG250 Gamma platform, utilizing the RG250 V-twin engine.

Key Updates:

MK1 (1994-1997) featured more aggressive styling and performance. The 1998 model (sometimes referred to as RS250 NIKY) saw minor updates and color scheme changes.

Production

Production Years:

1994 - 2003 (though this manual covers up to 1998)

Manufacturing Location:

Noale, Italy

🏆 Awards & Recognition

Recognitions

Motorcycle Press Reviews:

Generally received highly positive reviews for its performance, handling, and striking aesthetics, often praised as a 'proper' supersport for its era.

Ratings

Performance Benchmark:

Considered a benchmark for lightweight 2-stroke performance and handling in its class.

Certifications

Emissions Standards:

Compliant with emissions standards of its respective production years (may require specific tuning or aftermarket solutions for modern regulations).

🏆 Professional Vehicle Manual Information

Comprehensive technical documentation for maintenance, repair, and operation