🏷️ Basic Information Identification Make: Aprilia Model: RS250 Year: 1998 Product Name: Aprilia RS250 1998 Workshop Repair Service Manual Product Format: PDF Download 👋 Introduction Market Position Motorcycle Class: High-performance 2-stroke sportbike, renowned for its track-bred origins and agile handling. Target Audience: Enthusiasts and owners seeking to maintain, repair, and optimize their Aprilia RS250. Competitive Analysis Contemporary Rivals: Suzuki RGV250, Yamaha TZR250, Kawasaki KR-1S. The RS250 was often considered the most refined and technologically advanced of the 250cc two-stroke sportbikes. Key Features Performance Focus: Emphasizes the bike's powerful 2-stroke V-twin engine and race-derived chassis. Diagnostic Value: Provides essential information for diagnosing and resolving common issues specific to this model. 📋 Manual Details Coverage Areas Vehicle Variants Covered: All Models, Engines, Trim, Transmission Types for the 1998 Aprilia RS250 Page Count Estimated Page Count: Approx. 300-400 pages (typical for a full workshop manual of this era) Manual Type Manual Type: Workshop Repair Service Manual Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Engine Systems: Engine disassembly, assembly, tuning, carburation (Mikuni TM30-6 x2), lubrication, cooling (liquid-cooled), ignition system, exhaust system, engine management, troubleshooting engine performance issues, piston and cylinder wear limits. Transmission Drivetrain: Gearbox disassembly and assembly, clutch operation and maintenance (wet multi-plate), chain drive maintenance, lubrication, troubleshooting transmission noise and engagement. Chassis Suspension: Front fork (Showa USD) disassembly, assembly, seal replacement, oil viscosity and level, rear shock absorber adjustment and overhaul, swingarm maintenance, steering head bearing service, wheel bearing replacement. Braking System: Front brake system (dual discs, Brembo calipers), rear brake system (single disc, Brembo caliper), brake fluid type and replacement, bleeding procedures, pad and disc wear specifications, master cylinder and caliper overhaul. Electrical System: Wiring diagrams, lighting system, starter motor, battery maintenance, charging system (alternator, regulator/rectifier), ignition system components, troubleshooting electrical faults, component testing. Fuel System: Fuel tank maintenance, fuel lines, fuel petcock operation, carburetor setup and synchronization, jetting information for different atmospheric conditions. Bodywork Fairings: Fairing removal and installation, body panel repairs, seat maintenance, cosmetic component service. Procedures Included Routine Maintenance: Oil and filter changes, spark plug replacement, air filter cleaning/replacement, chain adjustment and lubrication, brake system checks, tire pressure monitoring, coolant level checks. Troubleshooting: Diagnostic procedures for common starting problems, poor running, electrical issues, braking faults, and chassis anomalies. Includes symptom-based troubleshooting guides. Major Repairs: Complete engine rebuilds, gearbox overhauls, suspension component refurbishment, brake caliper servicing, electrical component replacement. Technical Specifications: Detailed torque specifications for all fasteners, engine clearances, valve timing (if applicable, though not on this 2-stroke), fluid capacities, and component tolerances. Technical Depth Depth: Comprehensive, covering everything from basic user checks to full engine and chassis rebuilds. Suitable for both home mechanics and professional workshops. 📊 Manual Specifications File Format PDF Quality: High-resolution, searchable PDF with clear text and legible diagrams. Print Quality Printable: Yes, designed to be printed for convenient workshop use. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 90-degree V-twin, two-stroke Displacement: 249 cc (250 cm³) Bore X Stroke: 54 mm x 54.5 mm Compression Ratio: 7.5:1 (typical for this model, check manual for specifics) Power Output: Approx. 70-75 hp @ 11,500 rpm (stock, may vary by region/tuning) Torque Output: Approx. 38-40 Nm @ 10,000 rpm (stock) Performance Redline: 12,000 rpm Fuel System Carburetors: 2 x Mikuni TM30-6 (30mm flat slide constant velocity carburetors) Fuel Delivery: Pre-mix lubrication (oil injected into fuel system) and gasoline fuel Ignition Ignition System: Digital CDI with electronic ignition timing Cooling Cooling System: Liquid-cooled 🔧 Transmission Standard Transmission Type: 6-speed constant mesh Features Clutch Type: Wet multi-plate, cable-actuated Final Drive: Chain drive 📐 Dimensions Exterior Length: Approx. 1,990 mm (check specific model variant) Width: Approx. 720 mm (check specific model variant) Height: Approx. 1,140 mm (check specific model variant) Weights Dry Weight: Approx. 140 kg Wet Weight: Approx. 156 kg (with fluids) Fuel Capacity: 16 Liters 🛡️ Safety Features Ratings Safety Certification: Not applicable in the same way as modern cars; focuses on rider safety through design and component quality. Active Features Braking Performance: Dual front Brembo discs with four-piston calipers; single rear Brembo disc. Designed for rapid deceleration. Chassis Stability: Stiff aluminum twin-spar frame and responsive suspension contribute to high-speed stability. Passive Features Rider Protection: Fairing provides aerodynamic protection; chassis design prioritizes rider control. 💡 Technology Features Infotainment Instrumentation: Analog tachometer, speedometer, coolant temperature gauge, odometer, trip meter, and indicator lights. Driver Assistance Rider Aids: None (no electronic rider aids like ABS or traction control, typical for 1998 sportbikes). Connectivity Charging Port: No integrated USB or charging ports. 🔧 Maintenance Service Intervals Oil Change Interval: Every 4,000 km or annually (engine oil). Pre-mix oil injection system requires regular monitoring. Spark Plug Replacement: Every 6,000-8,000 km (NGK BR9EG or equivalent). Chain Maintenance: Lubricate every 500-1000 km, adjust chain slack as...