APRILIA RS250 Motorcycle Service & Repair Manual-PDF
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🏷️ Basic Information Identification Make: Aprilia Model: RS250 Model Designation: RS 250 Type: Sportbike Motorcycle 👋 Introduction Market Position Segment: Lightweight two-stroke sportbike, renowned for its performance and racing pedigree. Competitive Analysis Key Competitors: Yamaha YZF-R25 (later models), Suzuki RGV250, Honda NSR250 (if applicable to certain markets/years). Key Features Performance Focus: High-revving two-stroke engine, aggressive styling, agile handling, track-day capability. Manual Utility: Essential resource for owners and mechanics to maintain, repair, and restore the RS250 to optimal performance. 📋 Manual Details Coverage Areas Comprehensive Coverage: Complete tear down and rebuild, maintenance, troubleshooting, diagnostics, electrical systems, mechanical systems, bodywork. Page Count Estimated Pages: 300-500 pages (typical for comprehensive service manuals) Manual Type Type: Official Service & Repair Manual Language Language: English (assumed based on product description) Format Format: PDF 📖 Manual Coverage Systems Covered Engine: Two-stroke V-twin engine, top-end rebuild, bottom-end rebuild, cooling system, lubrication system, ignition system, fuel system (carburetors), exhaust system. Transmission: 6-speed sequential gearbox, clutch assembly, shift linkage, internal components. Brakes: Front and rear disc brake systems, caliper overhaul, master cylinder service, hydraulic lines, brake fluid specifications. Suspension: Front telescopic forks (e.g., Showa or Marzocchi depending on year), rear monoshock absorber, fork seal replacement, fork oil specifications, rear shock absorber adjustment and service. Electrical: Wiring diagrams, lighting system, charging system (alternator, rectifier/regulator), starter motor, battery, ignition system components, diagnostic troubleshooting. Chassis And Bodywork: Frame inspection, body panel removal/installation, seat, fuel tank, fairings, wheels, tires, steering system, swingarm. Procedures Included Routine Maintenance: Oil changes, chain adjustment and lubrication, air filter cleaning/replacement, spark plug replacement, coolant checks, brake fluid checks. Troubleshooting: Systematic diagnosis of common performance issues, starting problems, electrical faults, braking concerns, and suspension anomalies. Rebuilds: Complete engine teardown and reassembly, carburetor overhaul, fork and shock absorber rebuilds, brake caliper and master cylinder service. Adjustments: Carburetor synchronization, idle speed adjustment, chain slack adjustment, suspension pre-load and damping adjustments. Torque Specifications: Specific torque values for all fasteners and critical engine/chassis components. Technical Depth Depth: Comprehensive, covering all aspects from basic checks to full engine and component rebuilds, including detailed torque specifications and diagrams. Diagnostic Charts: Troubleshooting flowcharts and diagnostic tables for common problems. 📊 Manual Specifications File Format Digital Format: PDF (Portable Document Format) Print Quality Searchability: Searchable text for quick information retrieval. Image Quality: High-resolution pictures and part diagrams for clarity. Binding Type Binding: Not Applicable (Digital PDF) Paper Type Paper Quality: Not Applicable (Digital PDF) Coverage Areas Diagrams And Illustrations: Includes detailed pictures and part diagrams for all major components and systems. ⚙️ Engine Specifications Primary Engine Configuration: V-twin, two-stroke Displacement: 249 cc Bore X Stroke: 54.0 mm x 54.5 mm (typical) Cooling System: Liquid-cooled Reed Valve System: Yes, for enhanced induction. Power Output: Approx. 70-72 hp @ 11,000 rpm (depending on year and market regulations) Torque: Approx. 40-42 Nm @ 10,000 rpm (depending on year and market regulations) Fuel System Carburetors: Dual Mikuni TMX30 flat-slide carburetors (typical) Fuel Delivery: Petcock, gravity feed Premix Or Autolube: Autolube system (separate oil injection) Performance Acceleration: 0-100 km/h in approx. 4-5 seconds (depending on rider and conditions). 🔧 Transmission Standard Type: 6-speed, constant mesh, sequential Clutch: Wet multi-plate Features Gear Ratios: Specific gear ratios detailed in the manual (e.g., 1st: 2.5, 2nd: 1.8, 3rd: 1.4, 4th: 1.2, 5th: 1.0, 6th: 0.9) Final Drive: Chain drive 📐 Dimensions Exterior Length: Approx. 1970 mm (typical) Width: Approx. 700 mm (typical) Height: Approx. 1070 mm (typical) Ground Clearance: Approx. 130 mm (typical) Weights Dry Weight: Approx. 130-140 kg (typical) Fuel Tank Capacity: Approx. 14-16 liters (typical) Wheelbase: Approx. 1360 mm (typical) 🛡️ Safety Features Ratings Safety Features: N/A (Motorcycle safety is primarily rider-dependent and related to component integrity). Active Features Braking System: Dual front disc brakes, single rear disc brake. ABS was not typically offered on this model. Passive Features Chassis Design: Twin-spar aluminum frame for rigidity and handling stability. 💡 Technology Features Infotainment Features: Basic analog instrumentation: speedometer, tachometer, coolant temperature gauge, neutral indicator, turn signal indicators. No modern infotainment systems. Driver Assistance Features: N/A for a 2-stroke sportbike of this era. 🔧 Maintenance Service Intervals Oil Change: Every 3,000-5,000 km or annually, whichever comes first. Manual will specify precise interval. Spark Plug Replacement: Every 5,000-8,000 km. Manual will provide specific plug types and gap settings. Chain Maintenance: Lubrication and adjustment every 500-1,000 km. Replacement based on wear. Coolant Replacement: Every 2 years or as per manual recommendations. Fluid Specifications Engine Oil Type: High-quality 2-stroke motorcycle oil, TCW3 rated or equivalent (specified in manual). Transmission Oil: API GL-4 or GL-5 SAE 75W-90 synthetic gear oil (typical, manual to confirm). Brake Fluid: DOT 4 or DOT 5.1 (manual to confirm exact specification). Coolant: 50/50 mixture of ethylene glycol antifreeze and distilled water. Fork Oil Type: Specific viscosity grade (e.g., 5W, 10W) and volume per fork leg, detailed in the manual. Known Issues Power Valves:...
Front and rear disc brake systems, caliper overhaul, master cylinder service, hydraulic lines, brake fluid specifications.
Suspension:
Front telescopic forks (e.g., Showa or Marzocchi depending on year), rear monoshock absorber, fork seal replacement, fork oil specifications, rear shock absorber adjustment and service.
Electrical:
Wiring diagrams, lighting system, charging system (alternator, rectifier/regulator), starter motor, battery, ignition system components, diagnostic troubleshooting.
0-100 km/h in approx. 4-5 seconds (depending on rider and conditions).
🔧 Transmission
Standard
Type:
6-speed, constant mesh, sequential
Clutch:
Wet multi-plate
Features
Gear Ratios:
Specific gear ratios detailed in the manual (e.g., 1st: 2.5, 2nd: 1.8, 3rd: 1.4, 4th: 1.2, 5th: 1.0, 6th: 0.9)
Final Drive:
Chain drive
📐 Dimensions
Exterior
Length:
Approx. 1970 mm (typical)
Width:
Approx. 700 mm (typical)
Height:
Approx. 1070 mm (typical)
Ground Clearance:
Approx. 130 mm (typical)
Weights
Dry Weight:
Approx. 130-140 kg (typical)
Fuel Tank Capacity:
Approx. 14-16 liters (typical)
Wheelbase:
Approx. 1360 mm (typical)
🛡️ Safety Features
Ratings
Safety Features:
N/A (Motorcycle safety is primarily rider-dependent and related to component integrity).
Active Features
Braking System:
Dual front disc brakes, single rear disc brake. ABS was not typically offered on this model.
Passive Features
Chassis Design:
Twin-spar aluminum frame for rigidity and handling stability.
💡 Technology Features
Infotainment
Features:
Basic analog instrumentation: speedometer, tachometer, coolant temperature gauge, neutral indicator, turn signal indicators. No modern infotainment systems.
Driver Assistance
Features:
N/A for a 2-stroke sportbike of this era.
🔧 Maintenance
Service Intervals
Oil Change:
Every 3,000-5,000 km or annually, whichever comes first. Manual will specify precise interval.
Spark Plug Replacement:
Every 5,000-8,000 km. Manual will provide specific plug types and gap settings.
Chain Maintenance:
Lubrication and adjustment every 500-1,000 km. Replacement based on wear.
Coolant Replacement:
Every 2 years or as per manual recommendations.
Fluid Specifications
Engine Oil Type:
High-quality 2-stroke motorcycle oil, TCW3 rated or equivalent (specified in manual).
Transmission Oil:
API GL-4 or GL-5 SAE 75W-90 synthetic gear oil (typical, manual to confirm).
Brake Fluid:
DOT 4 or DOT 5.1 (manual to confirm exact specification).
Coolant:
50/50 mixture of ethylene glycol antifreeze and distilled water.
Fork Oil Type:
Specific viscosity grade (e.g., 5W, 10W) and volume per fork leg, detailed in the manual.
Known Issues
Power Valves:
Carbon build-up on power valves can affect performance; require periodic cleaning.
Carburetor Synchronization:
Can drift over time, requiring regular checks for smooth running.
Cylinder Wear:
As with any high-performance two-stroke, cylinder and piston wear can occur with hard use and if lubrication is not optimal.
Clutch Slippage:
Can occur with aggressive riding or incorrect adjustment.
📚 Vehicle History
Brand Heritage
Aprilia Legacy:
Aprilia has a strong racing heritage, particularly in smaller displacement categories and two-stroke racing, influencing the RS250's design and performance.
Model Evolution
Development Basis:
Derived from Suzuki RG250 'Gamba' platform, with Aprilia's own engine tuning and chassis refinement.
Engine Development:
Features Aprilia's own Rotax-derived 250cc V-twin 2-stroke engine with performance tuning.
Production
Production Years:
Mid-1990s to early 2000s (typically 1995-2004).
Manufacturing Location:
Italy
Notable Variants:
RS250 (standard), RS250 'Challenge' or 'Cup' versions (often with upgraded components for racing).
🏆 Awards & Recognition
Recognitions
Industry Acclaim:
Praised for its performance, handling, and pure two-stroke exhilaration, earning a cult following among enthusiasts.