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Aprilia

Aprilia RS250 1999 Service Repair Workshop Manual

Aprilia RS250 1999 Service Repair Workshop Manual

$16.99
$16.99
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Vehicle data plateRef 566516
Brand
Aprilia
Vehicle
Motorcycle
Models covered
Misc, Motorcycles, RS250
Years
1999
Format
PDF, searchable, print-ready
Delivery
Instant download after checkout
Language
English

What happens after you pay

  • Download link opens on the order page immediately
  • The same link is emailed to you — re-download any time
  • Open on phone, tablet or PC; print only the pages you need
  • Not sure it covers your model year? Ask us before you buy
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
RS250
Year:
1999
Generation
Generation Identifier:
MK II / RG250 Gamma based
Codes
Chassis Code:
AP08
👋 Introduction
Market Position
Bike Category:
Lightweight Sportbike
Target Audience:
Enthusiast owners, independent mechanics, racing teams
Competitive Analysis
Competitors 1999:
Yamaha YZF-R6, Suzuki GSX-R600, Kawasaki Ninja ZX-6R, Honda CBR600F
Key Features
Bike Philosophy:
Race-bred performance, lightweight chassis, potent 2-stroke power delivery
Manual Advantage:
Provides in-depth technical data for maintenance and repair that often exceeds standard owner's manuals.
📋 Manual Details
Coverage Areas
Primary Coverage:
Service, Repair, Workshop
Page Count
Estimated Pages:
300+
Manual Type
Type:
Workshop Manual
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Engine:
2-stroke V-twin, Cooling System, Lubrication System, Ignition System, Carburetion System, Exhaust System
Transmission:
6-speed Sequential Gearbox, Clutch System, Drive Chain
Chassis:
Frame, Swingarm, Suspension (Front & Rear), Steering System, Wheels, Tires
Brakes:
Front & Rear Disc Brakes, Hydraulic System, Caliper Maintenance
Electrical:
Wiring Harness, Lighting System, Battery, Charging System (Stator/Regulator), Starter Motor, Instruments, ECU
Bodywork:
Fairings, Seat, Fuel Tank, Body Panels, Seat Removal
Procedures Included
Routine Maintenance:
Oil Changes, Filter Replacements, Chain Adjustment, Spark Plug Service, Coolant Flush
Engine Rebuild:
Top-end Overhaul, Bottom-end Rebuild, Crankshaft & Piston Replacement, Cylinder Boring/Honing
Transmission Service:
Gearbox Disassembly/Reassembly, Clutch Plate Replacement, Shift Drum & Fork Alignment
Suspension Overhaul:
Fork Seal Replacement, Shock Absorber Rebuilding, Linkage Maintenance
Electrical Diagnostics:
Wiring Diagram Interpretation, Fault Finding, Component Testing, CDI Unit Diagnosis
Carburetor Tuning:
Jetting Adjustments, Synchronization, Idle Speed Control
Troubleshooting:
Common Problems, Diagnostic Flowcharts, Symptom-based Repair Guides
Technical Depth
Depth:
Comprehensive: From basic checks and adjustments to full engine and transmission rebuilds, including detailed electrical system diagnostics.
📊 Manual Specifications
File Format
File Type:
PDF
Print Quality
Image Resolution:
High-resolution scans for clear diagrams and text
Binding Type
Binding:
N/A (Digital)
Paper Type
Paper:
N/A (Digital)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, 70-degree V-twin, 2-stroke
Displacement:
249 cc
Bore X Stroke:
54.0 mm x 54.5 mm
Compression Ratio:
7.5:1
Valvetrain:
Reed Valve Intake, Rotary Disc Valve (on crankshaft)
Power Delivery System:
Suzuki's Automatic Exhaust Power VALVE System (SAEC)
Performance
Horsepower:
Approx. 70 hp @ 11,000 rpm (claimed)
Torque:
Approx. 30 lb-ft @ 10,000 rpm (claimed)
Fuel System
Carburetion:
Twin 32mm Mikuni TMR Flat-slide Carburetors
Fuel Type:
Premium Unleaded Gasoline (95 RON / 91 AKI)
Fuel Tank Capacity:
16 Liters (4.2 US gal)
Lubrication System
Oil Type:
2-Stroke Premix or Autolube Injection System
Autolube Oil Spec:
API-TC, JASO FD Certified Synthetic 2-Stroke Oil
🔧 Transmission
Standard
Gearbox Type:
6-speed Constant Mesh, Sequential
Features
Clutch Type:
Wet, Multi-plate
Final Drive:
O-ring Sealed Chain
📐 Dimensions
Exterior
Length:
Approx. 1970 mm (77.6 in)
Width:
Approx. 720 mm (28.3 in)
Height:
Approx. 1120 mm (44.1 in)
Wheelbase:
Approx. 1365 mm (53.7 in)
Weights
Dry Weight:
Approx. 142 kg (313 lbs)
Wet Weight:
Approx. 163 kg (359 lbs)
🛡️ Safety Features
Ratings
Frame Type:
Aluminum Twin-Spar (Gull-wing style)
Active Features
Front Suspension:
Inverted Telescopic Forks (Showa, 41mm stanchions), Adjustable Preload, Compression, and Rebound Damping
Rear Suspension:
Monoshock (Showa), Linkage-Type, Adjustable Preload, Compression, and Rebound Damping
Front Brakes:
Dual 320mm Discs with 4-piston Nissin Calipers
Rear Brakes:
Single 220mm Disc with 2-piston Nissin Caliper
Tires Front:
120/70ZR17
Tires Rear:
160/60ZR17
💡 Technology Features
Infotainment
Instrumentation:
Analog Tachometer, Speedometer, Temperature Gauge, Odometer, Trip Meter, Neutral Indicator, Turn Signal Indicators, High Beam Indicator
Driver Assistance
Electronic Aids:
None (pure analog sportbike)
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-5,000 km (1,800-3,100 miles) or annually
Spark Plug Replacement:
Every 6,000-8,000 km (3,700-5,000 miles)
Chain Lubrication Adjustment:
Every 500-1000 km (300-600 miles) and after washing/wet riding
Coolant Flush:
Every 2 years
Fluid Specifications
Engine Oil Type:
Fully synthetic 2-stroke oil, API-TC, JASO FD
Transmission Oil Type:
API GL-4 SAE 75W/90 or SAE 10W/40 Gear Oil
Coolant Type:
Ethylene Glycol-based Anti-freeze/Coolant (50/50 mix with distilled water)
Brake Fluid Type:
DOT 4
Known Issues
Common Wear Item:
Crankshaft Seals, Exhaust Power Valves (carbon buildup), Clutch Plates, Wheel Bearings
Electrical Gremlins:
Wiring loom degradation, CDI unit failure, regulator/rectifier issues
Performance Tuning Challenges:
Sensitivity to jetting changes, specific exhaust requirements
📚 Vehicle History
Brand Heritage
Manufacturer:
Aprilia S.p.A.
Brand Focus:
High-performance motorcycles, especially in racing disciplines
Model Evolution
Predecessor:
RS250 (MK I)
Engine Origin:
Derivative of Suzuki RG250 Gamma engine
Production
Production Period:
1995 - 2003
Key Manufacturing Location:
Noale, Italy
🏆 Awards & Recognition
Recognitions
Bike Reputation:
Highly regarded for its sharp handling, potent 2-stroke engine, and aggressive styling. A cult classic.
Ratings
Performance Rating:
Excellent performance for its displacement class, especially in acceleration and cornering.

Delivery & file format

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Check the model year and engine before you buy

Manufacturers change procedures, wiring and part numbers between model years and engine options. If your VIN plate shows a year or engine code that is not listed on the data plate above, contact us with the model, year and VIN and we will confirm coverage before you order.

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