The Aprilia RS 250 Challenge Version, produced between 1995 and 2004, is a high-performance sportbike renowned for its exceptional handling and potent two-stroke V-twin engine, derived from Suzuki RGV250 Gamma components. This model, often prepared for track use, embodies Aprilia's rich racing heritage and Italian engineering prowess. Its lightweight aluminum twin-spar frame, powerful braking system, and responsive chassis contribute to its reputation as a premier 250cc sportbike of its era, offering an engaging and pure riding experience focused on mechanical feedback and rider skill.
This comprehensive service manual provides in-depth technical features and servicing procedures for the Aprilia RS 250 Challenge Version, covering a wide array of systems including the fuel, cooling, engine, clutch, lubrication, transmission, wheels, tires, brakes, suspension, steering, frame, and electrical systems. It details routine maintenance, fluid changes, and detailed repair and diagnostic instructions for all major components, offering professional-level guidance equivalent to dealership technician manuals. This resource is essential for owners and technicians aiming to maintain the optimal performance and longevity of this specialized sportbike.
Model:
RS 250 Challenge Version
Engine Code:
RS 250 Challenge (Likely derived from Suzuki RG500 Gamma components)
Target Audience:
Aprilia RS 250 Challenge Version owners and technicians requiring in-depth service and repair information.
Value Proposition:
Provides dealership-level technical data, enabling users to perform complex maintenance and repairs, saving time and costs associated with professional servicing. Crucial for maintaining the performance and longevity of a specialized sportbike.
Manual Utility:
Comprehensive instructions and diagrams for high-quality repairs, facilitating understanding and efficient problem-solving. Acts as a professional reference book for bike maintenance.
Primary Coverage:
Technical features and servicing procedures for the Aprilia RS 250 Challenge Version (USA).
Estimated Page Count:
Unknown (Based on typical workshop manuals, likely several hundred pages)
Type:
Service Manual / Repair Manual
Format:
PDF Download (within a RAR archive)
Engine Systems:
Fuel System, Cooling System, Engine Top End, Clutch, Engine Lubrication System, Engine Removal/Installation, Crankshaft/Transmission, Carburetor Assembly, Fuel Pump, Fuel Filter, Air Filter
Chassis Systems:
Wheels/Tires, Final Drive, Brakes, Suspension, Steering, Frame, Electrical System
Maintenance Procedures:
Routine maintenance, oil changes, fluid changes, tire rotation, brake pad replacement, air filter replacement.
Repair Procedures:
Comprehensive instructions for fixing problems, detailed diagnostics and repair of all major systems.
Depth:
Professional level, equivalent to dealership technician manuals, covering everything from basic servicing to detailed repair and diagnosis.
Download Package:
RAR archive, requires WinRAR or compatible extraction software.
Printability:
Assumed to be printable due to PDF format, intended for professional use, implying good clarity of diagrams and text.
Binding:
N/A (Digital download)
Paper Type:
N/A (Digital download)
Engine Type:
Two-stroke, V-twin
Bore X Stroke:
54 mm x 54.5 mm
Horsepower Estimate:
Approx. 70-75 HP (stock, depending on year and market)
Torque Estimate:
Approx. 42 Nm (stock)
Carburetion:
Dual 32mm Mikuni TMR carburetors (typical for Challenge Version)
Fuel Type:
Unleaded gasoline (high octane recommended)
Lubrication Type:
Premix or Autolube (check specific model variant, autolube is common)
Type:
6-speed constant mesh
Clutch Type:
Wet, multi-plate
Final Drive:
Chain driven
Dry Weight:
Approx. 140 kg
Wet Weight:
Approx. 165 kg (fully fueled)
Length Overall:
Approx. 1980 mm
Width Handlebar:
Approx. 720 mm
Height Seat:
Approx. 810 mm
Wheelbase:
Approx. 1385 mm
Safety Features Overview:
Focus on rider control and braking; no electronic rider aids like ABS or traction control typically found on this model.
Braking System:
Dual front discs (e.g., 320mm) with 4-piston calipers, single rear disc with 2-piston caliper. Often featuring Brembo components.
Frame Design:
Aluminum twin-spar frame for rigidity and handling.
Dashboard Instruments:
Analog tachometer, speedometer, coolant temperature gauge, and indicator lights.
Rider Aids:
None; this is a pure performance sportbike focused on mechanical feedback and rider skill.
Connectivity Features:
N/A
Oil Change Interval:
Typically every 3,000-5,000 km or annually, depending on usage. Transmission oil change every 6,000-10,000 km.
Spark Plug Replacement:
Every 6,000-8,000 km (or as per manual specification, type NGK BR9EG or similar).
Coolant Type:
Ethylene glycol based antifreeze/coolant, 50/50 mix with distilled water.
Brake Fluid Type:
DOT 4 or DOT 5.1 (check manual for specific recommendation).
Transmission Oil Type:
SAE 10W-40 or 15W-50 motorcycle-specific gear oil (check manual for exact API GL rating and viscosity).
Common Wear Items:
Clutch plates, exhaust valve mechanism (if equipped), crankcase seals, ignition coils, carburetor synchronization.
Two Stroke Specific Concerns:
Proper oil-fuel mixture, decarbonizing exhaust ports and power valves, potential for piston ring wear if not maintained.
Aprilia Legacy:
Aprilia has a rich racing heritage, particularly in smaller displacement classes, known for producing high-performance sportbikes with advanced chassis and engine technology.
Rs250 Development:
The RS250 was developed from the highly successful Suzuki RGV250 Gamma, utilizing its V-twin two-stroke engine and chassis components, significantly enhancing performance and handling with Aprilia's Italian engineering and design flair.
Production Period:
Produced from 1995 to 2004.
Challenge Version Origin:
The 'Challenge Version' typically refers to a variant prepared or optimized for track day use or racing homologation, often featuring higher-spec components and tuning.
Motorcycle Press Reviews:
The Aprilia RS 250 was consistently praised by motorcycle journalists for its exceptional handling, powerful two-stroke engine, and premium components, often considered one of the best 250cc sportbikes of its era.
