1995–1997 Aprilia RS 250 Service Manual FSM

This 580-page PDF reproduces Aprilia's factory service and repair information for the RS 250 with the 249 cc, 90-degree V-twin two-stroke engine, reed induction, electronically controlled exhaust valves, separate oil injection, liquid cooling, and a six-speed gearbox. Aprilia expressly states that the publication is meant for professional mechanics and omits basic concepts it considers superfluous. It is therefore written for professional workshop use, not as a beginner's stand-alone maintenance guide; routine maintenance users are directed to the separate Use and Maintenance manual.

• Coverage and document layout: The front matter identifies a first edition from 1994 and a second edition from October 1998. Updated-page matrices group Models 1994-1997 and provide separate replacement pages for Model 1998. Version symbols distinguish automatic-light, Free Power, catalytic, optional, and market-specific configurations. The scan combines Italian pages with English and Spanish translations.
• Engine and transmission repair: Covers engine removal and chassis reinstallation, complete disassembly and reassembly, cylinder and piston inspection, crankshaft checks, clutch service, kick-starter work, transmission gear installation, and shift-fork clearance inspection.
• RAVE and oil-injection setup: Details the exhaust-valve actuator, pulley and cable assembly, cable adjustment, functional checks, oil-pump operation, actuator-to-pump cable setting, and air bleeding of the mixer-oil circuit.
• Fuel and cooling systems: Includes Mikuni TM34SS carburetor removal, disassembly, needle-valve and float inspection, fuel-level checking, carburetor synchronization, throttle and choke adjustment, radiator service, thermostat testing, and coolant-sensor diagnosis.
• Chassis, brakes, and suspension: Provides wheel and bearing service, tire work, brake-pad and disc inspection, hydraulic-circuit bleeding, steering-head repair, rear-suspension removal, and separate fork procedures for the right hydraulic-damping leg and left spring leg.
• Electrical testing and fault isolation: Handles the charging system, alternator, regulator/rectifier, CDI ignition, ignition checker, coils, pickup, throttle sensor, air solenoids, exhaust-valve actuator, switches, battery, instruments, lighting, and complete wiring diagrams.
• Workshop reference data: Supplies symptom/cause/remedy troubleshooting charts, component-specific torque tables, wear limits, clearances, electrical test values, lubricant and capacity data, cable and hose routing, and a numbered special-tool catalog.

Factory Repair Depth

The engine chapter supports a true bench repair rather than stopping at unit removal. Inspection data covers 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 pages identify transmission gear codes and orientation, the non-symmetrical shift pawl, oil-guide direction, specified sealants and locking compounds, and final manual function checks.

The Model 1998 update package replaces or supplements general specifications, the periodic-service chart, engine-removal information, cooling and electrical sections, bodywork, wheels, brakes, steering, fork service, torque data, and technical specifications. Separate ignition-check references are also provided for the 1996 25 kW version. Those distinctions matter when choosing wiring, carburetor, gearing, tire, suspension, or repair data for a particular build.

Diagrams, Schematics, and Special Tools

Useful visual references include the ignition-system schematic, the Model 1996 and updated RS 250 wiring diagrams, coolant-circuit layout, mixer-oil hose routing, fuel-hose routing, and exploded front-fork and steering views. The special-tool section identifies the rear and front support stands (8140194 and 8140195), fork-seal insertion tool (8140145), crankcase separator (8600389), clutch hub holder (8600391), and ignition checker with adapter and tester lead (8600397, 8600398, and 8600399).

Manual-Specific Cautions and Scope

A torn or poorly seated air-filter element can let unfiltered air bypass the foam and accelerate piston-ring and cylinder-bore wear. During fork repair, the slide-bushing surfaces and new seals are easily damaged; the manual calls for dedicated holding and insertion tools and protects the tube end during reassembly.

Use the specified support stands before wheel, steering, fork, or rear-suspension work, and follow the manual's warnings for brake fluid, fuel, and pressurized hot coolant. This publication references, but does not include, engine parts catalog 801W, chassis parts catalogs 380, 380T, 380T rel. 01, or 381W, nor the Aprilia Use and Maintenance manual 8102854.