Market Position:
The Aprilia RS 250 was a highly regarded, high-performance two-stroke sportbike known for its exceptional handling and aggressive styling, directly competing with other 250cc two-stroke machines of its era.
Competitors:
Honda NSR250R, Suzuki RGV250, Yamaha TZR250, Kawasaki KR-1S.
Handling:
Renowned for its agile chassis and superior cornering ability, a hallmark of Aprilia sportbikes.
Engine Technology:
Powered by a potent V-twin two-stroke engine, derived from Suzuki's RGV250 platform.
Design:
Aggressive sportbike styling with aerodynamic fairings and a race-inspired riding position.
Value:
Provides comprehensive, technician-level information to effectively maintain, diagnose, and repair the Aprilia RS 250, saving time and money on repairs.
Systems Covered:
General Information, Fuel System, Cooling System, Engine Top End, Clutch, Engine Lubrication System, Engine Removal/Installation, Crankshaft/Transmission, Wheels/Tires, Final Drive, Brakes, Suspension, Steering, Frame, Electrical System, Appendix
Page Count:
Estimated 300-400 pages (typical for a full workshop manual of this era, actual count not provided)
Manual Type:
Workshop Manual / Service Manual / Repair Manual / Factory Service Manual (FSM)
Format:
PDF Download (contained within a RAR archive)
Powertrain:
Engine (top end, lubrication, removal/installation, crankshaft, transmission), Clutch, Fuel System, Cooling System, Final Drive
Chassis:
Wheels, Tires, Brakes, Suspension, Steering, Frame
Electrical:
Complete Electrical System, Wiring Diagrams (implied by 'all information and diagrams')
Maintenance:
Routine checks, fluid changes, lubrication, filter replacements, tire rotation/replacement, brake pad/shoe replacement, spark plug replacement.
Diagnostics:
Troubleshooting for all systems, component testing, identifying common issues.
Repair Rebuild:
Complete engine rebuild procedures, transmission overhaul, suspension component replacement, brake system servicing, electrical component repair.
Installation Replacement:
Engine removal/installation, component replacement (e.g., clutch, suspension parts, electrical components).
Depth Of Coverage:
Comprehensive, suitable for dealership technicians, covering detailed disassembly, assembly, adjustments, specifications, and troubleshooting.
Diagnostic Procedures:
In-depth diagnostic trees and flowcharts for common and complex problems.
Torque Specifications:
Detailed torque values for all critical fasteners.
Wiring Diagrams:
Comprehensive electrical wiring diagrams for the entire motorcycle.
File Format:
RAR Archive containing PDF files
Required Software:
WinRAR or compatible archive extraction software (e.g., 7-Zip), PDF Reader
Compatibility:
All Versions of Windows & Mac
Print Quality:
High Quality, suitable for printing (PDF)
Binding Type:
N/A (Digital Download)
Paper Type:
N/A (Digital Download)
Configuration:
90° V-twin, two-stroke
Bore X Stroke:
54 x 54.5 mm
Cooling System:
Liquid-cooled
Valvetrain:
Reed valves, Rotary disc valve (Suzuki RG500 derived)
Horsepower:
Approx. 70-75 hp (depending on market restrictions and tuning)
Torque:
Approx. 32-34 Nm (24-25 lb-ft)
Carburetors:
Twin 32mm Mikuni TM32SS flat-slide carburetors
Fuel Type:
Unleaded gasoline (premium recommended), 2-stroke oil injection
Oil System:
Automatic 2-stroke oil injection system
Engine Removal Installation
Procedure Coverage:
Detailed steps for engine removal and installation, including necessary component disconnections and frame clearances.
Type:
6-speed constant mesh sequential
Gear Ratios:
Detailed ratios for each gear will be provided in the manual.
Clutch Type:
Wet multi-plate, cable-actuated
Clutch Servicing:
Procedures for clutch inspection, adjustment, replacement of friction plates, springs, and pressure plates.
Safety Ratings:
N/A (Motorcycle, typically not subject to automotive safety rating standards like NCAP)
Brakes:
Dual front disc brakes (320mm), Single rear disc brake (240mm), typically with 4-piston calipers.
Suspension:
Inverted telescopic front fork (e.g., Showa), Monoshock rear suspension (e.g., Öhlins or Showa).
Frame:
Lightweight aluminum twin-spar frame for rigidity and agility.
Infotainment System:
N/A (None present on this model, focused on raw performance).
Driver Assistance Features:
N/A (No electronic rider aids such as ABS, traction control, or ride modes).
Connectivity Features:
N/A
Oil Change:
2-stroke oil injection system requires regular monitoring and replenishment of the oil reservoir. Engine oil change intervals (if applicable for specific components) not specified but typically every few thousand miles for gearbox oil.
Spark Plugs:
Recommended replacement every 5,000-7,500 miles, depending on usage and plug type (e.g., NGK BR9EG).
Chain Sprocket:
Regular cleaning, lubrication, and adjustment of the drive chain; replacement typically around 15,000-25,000 miles depending on maintenance and riding style.
Engine Oil:
High-quality 2-stroke synthetic or semi-synthetic motorcycle oil (e.g., Motul 7100 2T, Castrol TTS).
Coolant:
Ethylene glycol-based antifreeze mixed with distilled water (50/50 ratio).
Brake Fluid:
DOT 4 or DOT 5.1 hydraulic brake fluid.
Transmission Oil:
API GL-4 or GL-5 75W-90 synthetic or mineral gear oil (e.g., Motul Gear 300).
Power Jet Carburetor:
The power jet carburetors can be sensitive to tuning and require precise adjustment for optimal performance. Issues with power jet circuits are common.
Two Stroke Engine:
Two-stroke engines, especially those derived from racing, can be more demanding in terms of maintenance (e.g., carbon buildup, frequent top-end rebuilds) compared to four-strokes.
Cylinder Wear:
Potential for cylinder and piston wear if not properly maintained or if subjected to excessive heat/over-revving.
Clutch Slipping:
Clutch slipping can occur with age or if ridden aggressively; requires clutch plate replacement.
Aprilia Heritage:
Aprilia has a strong racing pedigree, particularly in smaller displacement categories and two-stroke racing, which heavily influenced the development of the RS 250.
Development Basis:
The RS 250's design and engine were largely based on the Suzuki RGV250 Gamma, with Aprilia incorporating its own chassis design, suspension tuning, and styling. This collaboration was a key aspect of its development.
Production Years:
1994-2003 (with minor updates between generations)
Generations:
MK1 (1994-1997) and MK2 (1998-2003), with the manual covering the early MK1 (1997) and the introduction of the MK2 (1998).
