Aprilia RS 250 Service Manual 1995–1997

Aprilia's factory service and repair manual documents the RS 250's reed-induction two-stroke engine, electronically controlled RAVE exhaust-valve control, separate oil injection, liquid cooling, and chassis systems. The front matter identifies a 1994 first edition and an October 1998 second edition.

PDF Search, Chapter Access and Wiring Detail

Search and diagram detail: Service text is not searchable; embedded bookmarks open the main chapters. Small wiring labels require zooming. The 1996 wiring diagram is clearer at PDF p. 256 than its faint duplicate at PDF p. 352.

One printable 580-page PDF contains a 392-page main section and an 188-page Updates section, including one blank page and five notes pages already counted in the total. Italian pages are accompanied by English and Spanish translations.

Engine, RAVE and Chassis Service

Selected contents: These highlights cover major workshop topics. Other material includes fuel-tap and filter checks, plus multifunction-computer operation.

• Engine and transmission: Step-by-step engine removal and reinstallation, internal inspection and reassembly, clutch service, kick-starter work, transmission assembly, and shift-fork checks.

• RAVE and oil injection: Exhaust-valve actuator, pulley and cable assembly, adjustment and functional checks, actuator-to-pump cable setting, oil-delivery testing, and mixer-circuit air bleeding.

• Fuel and cooling: Mikuni TM34SS carburetor disassembly, needle-valve and float inspection, fuel-level checks, synchronization, throttle and choke adjustment, radiator service, thermostat testing, and coolant-sensor diagnosis.

• Wheels and brakes: Wheel-bearing replacement, tire removal and installation, brake-pad replacement, disc inspection, hydraulic-circuit bleeding, and steering-head service.

• Suspension: Rear-suspension removal and inspection, separate early-fork procedures for the damping and spring legs, and updated front-fork disassembly and reassembly.

• Electrical diagnosis: Alternator and regulator/rectifier tests, CDI ignition diagnosis, ignition-checker procedures, battery and switch testing, and lighting and instrument checks.

• Workshop reference data: Symptom/cause/remedy charts, component torque tables, wear limits, clearances, electrical test values, lubricant and capacity data, cable and hose routing, and a numbered special-tool catalog.

Written for professional mechanics, the manual omits some basic instruction and refers readers to the separate Use and Maintenance manual for ordinary maintenance.

Engine Inspection and Assembly Limits

Missing engine pages: Printed pages 3-52–3-55 and 3-62–3-63 are absent from this PDF, leaving gaps in the engine disassembly and inspection sections.

The remaining inspection material addresses the cylinder head and liner, pistons and rings, crankshaft runout, bearings and seals, clutch-plate wear and distortion, and shift-fork-to-groove clearance.

Reassembly details include gear orientation, the A/B shift-fork and sixth-gear compatibility table with part numbers, the asymmetrical shift pawl, oil-guide position, sealants, locking compounds, and manual function checks.

An air-filter element that is torn or incorrectly seated can admit unfiltered air and accelerate piston-ring and cylinder-bore wear.

Model Updates and Electrical Diagnosis

Updated-page matrices distinguish Models 1994-1997 from Model 1998 replacement pages. Revisions cover general specifications, the periodic-service chart, engine removal, cooling and electrical systems, bodywork, wheels, brakes, steering, fork service, torque data, and technical specifications.

Automatic-light (ASD), Free Power (FP), catalytic, optional, and market symbols identify configuration differences. Separate ignition-check references address the 1996 25 kW version. These distinctions help match carburetor, gearing, tire, suspension, wiring, and repair information to the vehicle.

Coil, pickup, and throttle-sensor tests include resistance or continuity data. Related checks cover air solenoids, the exhaust-valve actuator, neutral and oil-level indicators, and instruments.

Fork and Rear-Suspension Scope

The early fork separates right-leg hydraulic damping from the left-leg spring. Model 1998 fork procedures describe matching internal components in both legs.

Swingarm and linkage work includes bearing inspection and replacement. The rear shock is checked and adjusted; a faulty unit is replaced complete with its reservoir.

Fork cautions identify possible damage to slide-bushing surfaces and new seals. The reassembly illustrations show dedicated holding and insertion tools and protection for the tube end.

Circuit Drawings and Workshop Tools

Illustrations include the ignition-system schematic, 1996 and updated vehicle wiring diagrams, coolant-circuit layout, mixer-oil and fuel-hose routing, and exploded fork and steering views.

Tool references identify rear and front support stands (8140194 and 8140195), fork-seal insertion tool (8140145), crankcase separator (8600389), clutch hub holder (8600391), and ignition checker, adapter, and tester lead (8600397, 8600398, and 8600399).

Workshop Precautions and Companion Manuals

Use the specified support stands for wheel, steering, fork, and rear-suspension work, and follow the manual's precautions for brake fluid, fuel, and hot pressurized coolant.

This PDF does not include the referenced companion publications: engine parts catalog 801W; chassis parts catalogs 380, 380T, 380T rel. 01, and 381W; and Use and Maintenance manual 8102854.

Exhaust-Valve and Oil-Pump Data Samples

The left-cylinder exhaust-valve cable specification is approximately 3.5 mm of lateral inner-cable deflection; the right-cylinder specification is 0.8–1.2 mm of cable play. The illustrations distinguish the measurement points.

Oil-pump test data specifies a delivery of 4.8–6.0 mL over two minutes at 2,000 rpm, with the pump lever held fully open.