Aprilia RS 250 1994 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Aprilia Model: RS 250 Year: 1994 Generation Model Generation: First Generation (MK1) Codes Chassis Code: AP01 Engine Code Family: Rotax V2 (Derivative of Suzuki RGV250)...

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Tipo: Motorcycle

Proveedor:

SKU: 358076

Etiquetas: 1994 Aprilia Motorcycle Motorcycles RS 250 RS Models

Variantes de producto

Descripción

🏷️ Basic Information

Identification

Make:

Aprilia

Model:

RS 250

Year:

Generation

Model Generation:

First Generation (MK1)

Codes

Chassis Code:

Engine Code Family:

Rotax V2 (Derivative of Suzuki RGV250)

👋 Introduction

Market Position

Segment:

Lightweight Two-Stroke Sportbike

Target Audience:

Performance-oriented riders, track day enthusiasts, and classic sportbike collectors.

Competitive Analysis

Key Competitors 1994:

Yamaha YZF600R, Kawasaki Ninja ZX-6, Suzuki GSX-R600 (though RS 250 occupied a niche)

Unique Selling Proposition:

Potent 250cc two-stroke V-twin engine, exceptional handling derived from Grand Prix racing technology, lightweight chassis.

Key Features

Engine Type:

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

Induction System:

Reed valve induction, Twin Mikuni TM33SS carburetors

Power Delivery:

Vibrant mid-range and top-end powerband characteristic of two-stroke engines.

Suspension Design:

Telescopic front forks (often with adjustable preload and damping), Monoshock rear suspension.

Braking System:

Dual disc front brakes, single disc rear brake, often with prominent Brembo or similar high-performance components.

📋 Manual Details

Coverage Areas

Main Coverage:

Complete Workshop Procedures for Aprilia RS 250 (1994 Model Year)

Additional Coverage:

Electrical Diagrams, Torque Settings, Fluid Capacities

Page Count

Estimated Page Count:

Manual Type

Type:

Factory Service Repair Manual

Language

Language:

English

Format

Digital Format:

File Requirements:

Adobe PDF Reader, WinZip

Viewing Features:

Zoom In/Out Capability

Compatibility

Operating Systems:

All Versions of Windows & Mac

📖 Manual Coverage

Systems Covered

Engine:

Complete engine overhaul, top-end and bottom-end procedures, piston, cylinder, crankshaft, and gearbox disassembly/assembly.

Fuel System:

Carburetor (Mikuni T M33SS) disassembly, cleaning, adjustment, fuel tank, fuel pump, and fuel lines.

Lubrication System:

Oil injection system, oil pump, oil tank, and lubrication points.

Cooling System:

Radiator, coolant hoses, water pump, thermostat, and bleeding procedures.

Electrical System:

Ignition system, charging system (alternator, regulator/rectifier), battery, lighting, starter motor, and comprehensive wiring diagrams.

Chassis:

Frame inspection, suspension (front forks, rear shock absorber), steering system, wheel bearings, and swingarm.

Brakes:

Front and rear brake systems, caliper overhaul, master cylinder service, brake fluid replacement, and bleeding.

Bodywork And Trim:

Fairing removal and installation, seat, fuel tank mounting, and other body panels.

Wheels And Tires:

Tire replacement, wheel balancing, and spoke tensioning (if applicable).

Procedures Included

Maintenance:

Periodic maintenance checks, fluid level checks, lubrication, filter replacement (air, oil - if applicable).

Tune Up:

Spark plug replacement and gapping, carburetor synchronization and adjustment, ignition timing checks.

Repair And Rebuild:

Detailed step-by-step instructions for component disassembly, inspection, repair, and reassembly for all major systems.

Troubleshooting:

Diagnostic procedures for common problems, fault finding based on symptoms.

Specifications:

Torque specifications for all fasteners, fluid capacities, tolerances, and adjustment specifications.

Updates:

Information on any service bulletins or updates applicable to the 1994 model.

Technical Depth

Depth:

Comprehensive, from basic owner maintenance to complete engine and chassis rebuilds, suitable for professional technicians and experienced DIY mechanics.

📊 Manual Specifications

File Format

File Type:

Digital (PDF)

Searchability:

Likely text-searchable within PDF reader

Print Quality

Printability:

Printable for physical reference

Binding Type

Binding Type:

N/A (Digital Format)

Paper Type

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Configuration:

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

Displacement:

249 cc

Bore X Stroke:

54 mm x 54.5 mm (approximate, derived from RGV250)

Compression Ratio:

7.5:1 (approximate, can vary by market/tune)

Cooling Method:

Liquid-cooled

Reed Block Design:

Petal reed valves

Performance

Horsepower:

Approx. 65-70 HP (at crankshaft, depending on market restrictions)

Torque:

Approx. 35-38 Nm (at crankshaft)

Redline:

Approx. 11,500 - 12,000 RPM

Fuel System

Carburetor Type:

Twin Mikuni TM33SS flat-slide carburetors

Fuel Delivery:

Gravity feed with electric fuel pump (for crossover)

Fuel Type:

Unleaded gasoline (minimum 95 RON)

Oil Injection:

Automatic oil injection system

🔧 Transmission

Standard

Type:

6-speed constant mesh

Gear Ratios:

Specific ratios detailed in manual, optimized for performance.

Clutch Type:

Wet multi-plate, cable-actuated

Features

Shift Pattern:

1 down, 5 up

Final Drive:

Chain drive

Transmission Fluid Type:

Specific gear oil (e.g., API GL-4, SAE 75W/90 or 80W/90 - consult manual for exact specification)

📐 Dimensions

Exterior

Length:

Approx. 1970 mm (77.6 in)

Width:

Approx. 700 mm (27.6 in)

Height:

Approx. 1125 mm (44.3 in)

Wheelbase:

Approx. 1360 mm (53.5 in)

Weights

Dry Weight:

Approx. 134 kg (295 lbs)

Wet Weight:

Approx. 150 kg (330 lbs) (with fluids)

Fuel Capacity:

16 Liters (4.2 US gal)

Oil Capacity:

Approx. 1.5 Liters (for 2T oil reservoir)

Dimensions

Seat Height:

Approx. 810 mm (31.9 in)

🛡️ Safety Features

Ratings

Crash Test Results:

N/A (Motorcycle)

Active Features

Braking Performance:

Dual front disc brakes (e.g., 320mm) and rear disc brake, providing strong stopping power.

Suspension Stability:

Well-tuned suspension provides excellent road holding and stability.

Lighting:

Halogen headlight, taillight, and turn signals for visibility.

Passive Features

Chassis Integrity:

Robust twin-spar aluminum frame designed for rigidity and handling.

Rider Ergonomics:

Sportbike riding posture, which can be demanding but offers control.

💡 Technology Features

Infotainment

Infotainment System:

N/A (Basic Sportbike Design)

Driver Assistance

Driver Assistance Features:

N/A (Emphasis on rider skill and feedback)

Engine Management

Ignition System:

Digital CDI ignition system with ignition timing adjustments.

Power Valve Control:

Mechanical operation of exhaust powervalves for broader power delivery.

🔧 Maintenance

Service Intervals

Oil Change Engine:

Recommended at specified mileage intervals or as per manual, typically every few thousand miles for gearbox oil.

Spark Plug Replacement:

Recommended at intervals of 3,000-5,000 miles or annually.

Air Filter Cleaning Replacement:

Check and clean/replace every 3,000-5,000 miles, depending on operating conditions.

Coolant Replacement:

Recommended every 1-2 years.

Chain Lubrication:

Regularly, every 300-500 miles and after riding in wet conditions.

Brake Fluid Replacement:

Recommended every 1-2 years to maintain performance and prevent corrosion.

Fluid Specifications

Engine Oil Type:

Two-stroke motorcycle oil, specifically for liquid-cooled, high-performance engines (e.g., Castrol TTS, Motul 710 2T or equivalent).

Cooling Fluid Type:

Mixture of distilled water and ethylene glycol-based antifreeze (typically 50/50 mix).

Brake Fluid Type:

DOT 4 (or DOT 5.1 if specified by manual for higher boiling point).

Known Issues

Two Stroke Maintenance:

Two-stroke engines require diligent maintenance, including proper oil mixing and attention to carbon buildup in exhaust ports and power valves.

Power Valves:

Mechanical power valves can seize if not properly cleaned and lubricated, impacting performance.

Carburetor Tuning:

Mikuni TM33SS carburetors require precise synchronization and jetting for optimal performance, especially at different altitudes or with aftermarket exhausts.

Clutch Wear:

Clutch plates can wear due to aggressive riding; regular inspection and replacement are necessary.

Electrical Connections:

As with many bikes of this era, electrical connections can be prone to corrosion or loosening; regular checks are advised.

📚 Vehicle History

Brand Heritage

Brand Origins:

Italian manufacturer with a strong racing pedigree, particularly in Grand Prix motorcycle racing.

Model Evolution

Development Basis:

Heavily based on the Suzuki RGV250 Gamma, utilizing its engine and chassis design principles, with Aprilia modifications and styling.

Significance:

A highly acclaimed lightweight supersport that offered performance comparable to larger capacity bikes, known for its precise handling and rev-happy two-stroke engine.

Model Line Introduction:

The RS 250 was introduced in 1995, but the 1994 model year refers to the earliest production models, often considered the MK1 variant.

Production

Production Period:

1995-2003 (with significant updates over the years)

Manufacturing Location:

Italy

🏆 Awards & Recognition

Recognitions

Bike Magazine Reviews:

Consistently received high praise from contemporary motorcycle publications for its performance and handling.

Ratings

Handling Evaluation:

Widely regarded as one of the best-handling motorcycles of its displacement class.

Certifications

Homologation:

Street-legal sportbike homologated for various global markets.