Aprilia RS250 RS 250 945W 1998 Service Repair Workshop Manual
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🏷️ Basic Information
Identification
Make:
Aprilia
Model:
RS250
Year:
1998
Codes
Internal Model Code:
945W
👋 Introduction
Market Position
Positioning:
High-performance, track-inspired 250cc two-stroke sportbike
Competitive Analysis
Competitors:
Yamaha YZF-R250, Honda CBR250RR (MC28), Suzuki RGV250
Key Features
Engine Type:
V-twin, two-stroke, liquid-cooled
Design Inspiration:
Based on Suzuki RG250 Gamma VJ22A platform, renowned for its sharp handling and potent engine
📋 Manual Details
Coverage Areas
Primary Coverage:
Service, Repair, Workshop
Page Count
Estimated Pages:
300-400
Manual Type
Type:
Workshop Manual / Service Manual
Language
Language:
English
Format
Format:
Digital (Likely PDF)
📖 Manual Coverage
Systems Covered
Engine:
Complete overhaul, tuning, ignition, cooling, lubrication, fuel system (carburetor specifics)
Transmission:
Gearbox disassembly, assembly, clutch operation, gear change mechanism
Chassis:
Frame inspection, suspension (front forks, rear shock), steering, wheels, brakes (hydraulic system, calipers, discs)
Electrical:
Wiring diagrams, lighting, ignition system, battery, charging system, instrumentation, sensors
Fuel System:
Carburetor jetting, float bowl adjustment, fuel lines, fuel tank
Procedures Included
Maintenance:
Regular servicing, fluid changes, chain adjustment, brake pad replacement, spark plug service
Troubleshooting:
Diagnosis of common problems, fault finding guides, electrical issue resolution
Repair:
Engine rebuild, gearbox repair, suspension overhaul, brake caliper servicing, exhaust system maintenance
Disassembly Assembly:
Step-by-step instructions for component removal and reinstallation
Technical Depth
Depth:
Comprehensive (from basic maintenance to full engine rebuilds and electrical system diagnosis)
Diagnostic Information:
Detailed fault codes, symptom analysis, and diagnostic procedures
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Text-searchable (OCR applied if necessary)
Print Quality
Printability:
High-resolution images and diagrams for clear printing
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, 90-degree V-twin, two-stroke
Displacement:
249 cc (249 cm³)
Bore X Stroke:
54.0 mm x 54.5 mm
Compression Ratio:
7.1:1 (for 1998 model)
Ignition System:
CDI (Capacitor Discharge Ignition)
Lubrication:
Premix or Autolube system (manual will detail both maintenance and troubleshooting)
Performance
Horsepower:
Approximately 70-75 HP (at crank, depending on market and tuning)
Torque:
Approximately 30-33 lb-ft (at crank)
Fuel System
Carburetors:
Twin Mikuni TM34SS flat-slide carburetors
Fuel Type:
Unleaded gasoline (91 octane or higher recommended)
Engine Codes
Engine Serial Number Location:
Stamped on crankcase (manual will specify exact location)
🔧 Transmission
Standard
Type:
6-speed constant mesh sequential gearbox
Features
Clutch:
Wet multi-plate clutch
Final Drive:
Chain drive
📐 Dimensions
Exterior
Length:
Approximately 1980 mm
Width:
Approximately 710 mm
Height:
Approximately 1135 mm
Wheelbase:
Approximately 1360 mm
Weights
Dry Weight:
Approximately 142 kg
Wet Weight:
Approximately 157 kg (fully fueled)
Tires
Front Tire Size:
120/70-ZR17
Rear Tire Size:
160/60-ZR17
Fuel Capacity
Fuel Tank Capacity:
16 Liters
🛡️ Safety Features
Ratings
Safety Ratings:
N/A (Motorcycle safety is typically assessed through handling dynamics and braking performance)
Active Features
Braking System:
Dual 320mm front discs with 4-piston calipers, 220mm rear disc with 2-piston caliper
Suspension Type:
Front: 41mm inverted telescopic fork (adjustable preload/rebound on some variants), Rear: Monoshock (adjustable preload/rebound)
Passive Features
Frame Construction:
Aluminum alloy twin-spar frame
💡 Technology Features
Infotainment
Infotainment System:
N/A (Basic analog instrumentation)
Performance Enhancements
Engine Management:
Electronic Power Valve (EPV) system for improved low-end and mid-range power delivery.
Suspension Technology:
Inverted front forks and adjustable rear monoshock for superior damping and handling characteristics.
🔧 Maintenance
Service Intervals
Oil Change:
Every 3,000-5,000 km or annually (refer to manual for precise interval and oil type)
Spark Plug Replacement:
Every 6,000-10,000 km (specific plug types will be detailed in manual)
Chain Adjustment:
Every 1,000 km or as needed
Fluid Specifications
Engine Oil:
High-quality 2-stroke engine oil, specific API/JASO rating (e.g., JASO FD) to be confirmed in manual.
Coolant:
Ethylene glycol-based coolant, 50/50 mix with distilled water.
Brake Fluid:
DOT 4 or DOT 5.1
Transmission Oil:
SAE 75W/90 or 10W/40 motorcycle gear oil (capacity specified in manual).
Known Issues
Common Problems:
Carburetor jetting sensitivity, exhaust valve issues (RVE), water pump seals, starter motor reliability, power valve cable stretching.
Preventative Maintenance:
Regular cleaning and adjustment of carburetors, proper autolube system maintenance, checking exhaust valve operation, coolant flush, and timely brake fluid changes are crucial.
📚 Vehicle History
Brand Heritage
Aprilia History:
Italian manufacturer known for its success in Grand Prix motorcycle racing, particularly in the 125cc and 250cc classes.
Model Evolution
Rs250 Development:
Developed in collaboration with Suzuki, utilizing their highly successful RG250 Gamma VJ22A platform, but with Aprilia's own chassis tuning, bodywork, and electrical components. It represented Aprilia's entry into the high-performance 250cc sportbike segment.
Production
Production Years:
1995-2003
Manufacturing Location:
Italy
🏆 Awards & Recognition
Recognitions
Historical Accolades:
While specific awards for the 1998 model are not widely documented, the RS250 platform was highly regarded by the press and enthusiasts for its performance and handling, often praised in period reviews against its competitors.
Step-by-step instructions for component removal and reinstallation
Technical Depth
Depth:
Comprehensive (from basic maintenance to full engine rebuilds and electrical system diagnosis)
Diagnostic Information:
Detailed fault codes, symptom analysis, and diagnostic procedures
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Text-searchable (OCR applied if necessary)
Print Quality
Printability:
High-resolution images and diagrams for clear printing
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, 90-degree V-twin, two-stroke
Displacement:
249 cc (249 cm³)
Bore X Stroke:
54.0 mm x 54.5 mm
Compression Ratio:
7.1:1 (for 1998 model)
Ignition System:
CDI (Capacitor Discharge Ignition)
Lubrication:
Premix or Autolube system (manual will detail both maintenance and troubleshooting)
Performance
Horsepower:
Approximately 70-75 HP (at crank, depending on market and tuning)
Torque:
Approximately 30-33 lb-ft (at crank)
Fuel System
Carburetors:
Twin Mikuni TM34SS flat-slide carburetors
Fuel Type:
Unleaded gasoline (91 octane or higher recommended)
Engine Codes
Engine Serial Number Location:
Stamped on crankcase (manual will specify exact location)
🔧 Transmission
Standard
Type:
6-speed constant mesh sequential gearbox
Features
Clutch:
Wet multi-plate clutch
Final Drive:
Chain drive
📐 Dimensions
Exterior
Length:
Approximately 1980 mm
Width:
Approximately 710 mm
Height:
Approximately 1135 mm
Wheelbase:
Approximately 1360 mm
Weights
Dry Weight:
Approximately 142 kg
Wet Weight:
Approximately 157 kg (fully fueled)
Tires
Front Tire Size:
120/70-ZR17
Rear Tire Size:
160/60-ZR17
Fuel Capacity
Fuel Tank Capacity:
16 Liters
🛡️ Safety Features
Ratings
Safety Ratings:
N/A (Motorcycle safety is typically assessed through handling dynamics and braking performance)
Active Features
Braking System:
Dual 320mm front discs with 4-piston calipers, 220mm rear disc with 2-piston caliper
Suspension Type:
Front: 41mm inverted telescopic fork (adjustable preload/rebound on some variants), Rear: Monoshock (adjustable preload/rebound)
Passive Features
Frame Construction:
Aluminum alloy twin-spar frame
💡 Technology Features
Infotainment
Infotainment System:
N/A (Basic analog instrumentation)
Performance Enhancements
Engine Management:
Electronic Power Valve (EPV) system for improved low-end and mid-range power delivery.
Suspension Technology:
Inverted front forks and adjustable rear monoshock for superior damping and handling characteristics.
🔧 Maintenance
Service Intervals
Oil Change:
Every 3,000-5,000 km or annually (refer to manual for precise interval and oil type)
Spark Plug Replacement:
Every 6,000-10,000 km (specific plug types will be detailed in manual)
Chain Adjustment:
Every 1,000 km or as needed
Fluid Specifications
Engine Oil:
High-quality 2-stroke engine oil, specific API/JASO rating (e.g., JASO FD) to be confirmed in manual.
Coolant:
Ethylene glycol-based coolant, 50/50 mix with distilled water.
Brake Fluid:
DOT 4 or DOT 5.1
Transmission Oil:
SAE 75W/90 or 10W/40 motorcycle gear oil (capacity specified in manual).
Known Issues
Common Problems:
Carburetor jetting sensitivity, exhaust valve issues (RVE), water pump seals, starter motor reliability, power valve cable stretching.
Preventative Maintenance:
Regular cleaning and adjustment of carburetors, proper autolube system maintenance, checking exhaust valve operation, coolant flush, and timely brake fluid changes are crucial.
📚 Vehicle History
Brand Heritage
Aprilia History:
Italian manufacturer known for its success in Grand Prix motorcycle racing, particularly in the 125cc and 250cc classes.
Model Evolution
Rs250 Development:
Developed in collaboration with Suzuki, utilizing their highly successful RG250 Gamma VJ22A platform, but with Aprilia's own chassis tuning, bodywork, and electrical components. It represented Aprilia's entry into the high-performance 250cc sportbike segment.
Production
Production Years:
1995-2003
Manufacturing Location:
Italy
🏆 Awards & Recognition
Recognitions
Historical Accolades:
While specific awards for the 1998 model are not widely documented, the RS250 platform was highly regarded by the press and enthusiasts for its performance and handling, often praised in period reviews against its competitors.