Aprilia RS250 Project
Discussion
Honestly, I’d be tempted to put a couple of litres of fresh fuel in it and give it a good kick.
You might be pleasantly surprised how it runs and if not or not very well, you’ll know what direction to take.
One thing to do though is put a little 2T oil in the tank. If the 2T oil pump is gummed up it might not flow well especially to the LH main bearing which is susceptible to running dry. Don’t ride the bike but if it’s running with a little premix in the tank it’ll allow you to check the oil pump is working properly.
You might be pleasantly surprised how it runs and if not or not very well, you’ll know what direction to take.
One thing to do though is put a little 2T oil in the tank. If the 2T oil pump is gummed up it might not flow well especially to the LH main bearing which is susceptible to running dry. Don’t ride the bike but if it’s running with a little premix in the tank it’ll allow you to check the oil pump is working properly.
Edited by Steve Bass on Monday 23 October 00:59
That's a great find and look forward to see it progress.
I've got a VJ22 RGV, same engine as the RS, had mine 10 years built it up from a rolling box of bits.
The crankcases do split , the front quarter of it holds the crank in, the gearbox is a cassette type, the whole cluster slides in from the side.
As said try Sean at The tuning works for spares.
I wouldn't try running it without inspecting the power valves as a minimum.. Their design are a set of sliding blades that protrude into the port, they have a roll pin in the middle which limits the travel, if the pin wears the blades hit the piston. Later versions had a thicker pin but still prone to failing. They also gum up and stop sliding.
My RGV.
I've got a VJ22 RGV, same engine as the RS, had mine 10 years built it up from a rolling box of bits.
The crankcases do split , the front quarter of it holds the crank in, the gearbox is a cassette type, the whole cluster slides in from the side.
As said try Sean at The tuning works for spares.
I wouldn't try running it without inspecting the power valves as a minimum.. Their design are a set of sliding blades that protrude into the port, they have a roll pin in the middle which limits the travel, if the pin wears the blades hit the piston. Later versions had a thicker pin but still prone to failing. They also gum up and stop sliding.
My RGV.
Thanks again for all the info - I am doing exactly that and spending some time researching! As much as I am tempted to try and get it running I think I am going for refurb everything and go from from there - I have found a few smaller spots of mould in airbox!
Will be fairly slow moving as only get to where it is being kept during the week but once apart can take the engine and carbs into work.
Keep forgetting how much they share with the RGV so a lot of engine and carb bits will come from Suzuki - I get a decent discount which makes the prices sensible, will use The Tuning works for everything else, sounds like the place to go and from what I can tell is linked to the RGV forum?
Suspension is waiting, want to get it registered and through with no surprises before I spend the money there. Likewise tyres are new but 4/5 years old so will get me through registering and running in then will go for something sticky.
Starting to think its going to be a keeper so will really go for replacing, cleaning and upgrading anything it needs.
Once the engine is apart will see the condition of the barrels and consider a replate, if its borderline then will just get it done. Pistons from Suzuki and most likely the barrels off to Millennium in the USA as can share shipping with some work bits.
Think I am working at Silverstone this weekend so could be a couple of weeks before I get to it again but will then get it apart and the engine out.
Will be fairly slow moving as only get to where it is being kept during the week but once apart can take the engine and carbs into work.
Keep forgetting how much they share with the RGV so a lot of engine and carb bits will come from Suzuki - I get a decent discount which makes the prices sensible, will use The Tuning works for everything else, sounds like the place to go and from what I can tell is linked to the RGV forum?
Suspension is waiting, want to get it registered and through with no surprises before I spend the money there. Likewise tyres are new but 4/5 years old so will get me through registering and running in then will go for something sticky.
Starting to think its going to be a keeper so will really go for replacing, cleaning and upgrading anything it needs.
Once the engine is apart will see the condition of the barrels and consider a replate, if its borderline then will just get it done. Pistons from Suzuki and most likely the barrels off to Millennium in the USA as can share shipping with some work bits.
Think I am working at Silverstone this weekend so could be a couple of weeks before I get to it again but will then get it apart and the engine out.
MK3 Dan said:
Anyone tried any of the ebay carb rebuild kits? Any good?
Zero experience with the RS250 (beyond it being a bike I wanted but never bought) but 99.9% of the carb rebuild kits for *any* bike are a bag of crap. Go with original (either Aprilia, Suzuki or Mikuni) parts every time. MK3 Dan said:
Thanks again for all the info - I am doing exactly that and spending some time researching! As much as I am tempted to try and get it running I think I am going for refurb everything and go from from there - I have found a few smaller spots of mould in airbox!
Will be fairly slow moving as only get to where it is being kept during the week but once apart can take the engine and carbs into work.
Keep forgetting how much they share with the RGV so a lot of engine and carb bits will come from Suzuki - I get a decent discount which makes the prices sensible, will use The Tuning works for everything else, sounds like the place to go and from what I can tell is linked to the RGV forum?
Suspension is waiting, want to get it registered and through with no surprises before I spend the money there. Likewise tyres are new but 4/5 years old so will get me through registering and running in then will go for something sticky.
Starting to think its going to be a keeper so will really go for replacing, cleaning and upgrading anything it needs.
Once the engine is apart will see the condition of the barrels and consider a replate, if its borderline then will just get it done. Pistons from Suzuki and most likely the barrels off to Millennium in the USA as can share shipping with some work bits.
Think I am working at Silverstone this weekend so could be a couple of weeks before I get to it again but will then get it apart and the engine out.
When I get back from my business trip I’ll post a picture of the engine stand I made for working on it. Makes life easier for setting up the barrels and head squish, power valves etc. Will be fairly slow moving as only get to where it is being kept during the week but once apart can take the engine and carbs into work.
Keep forgetting how much they share with the RGV so a lot of engine and carb bits will come from Suzuki - I get a decent discount which makes the prices sensible, will use The Tuning works for everything else, sounds like the place to go and from what I can tell is linked to the RGV forum?
Suspension is waiting, want to get it registered and through with no surprises before I spend the money there. Likewise tyres are new but 4/5 years old so will get me through registering and running in then will go for something sticky.
Starting to think its going to be a keeper so will really go for replacing, cleaning and upgrading anything it needs.
Once the engine is apart will see the condition of the barrels and consider a replate, if its borderline then will just get it done. Pistons from Suzuki and most likely the barrels off to Millennium in the USA as can share shipping with some work bits.
Think I am working at Silverstone this weekend so could be a couple of weeks before I get to it again but will then get it apart and the engine out.
be careful to check the crank condition. I don’t think there’s any new ones left so rebuilding is the only option.
Barrels are not available so guard yours with your life!!!
Last time I checked with Sean, carb parts were still unavailable due to Covid but hopefully that’s changed. I need to change my jetting from the Johannesburg altitude to the Ontario sea level and humidity.
Something else that was incredibly useful for setting up the engine is an rpm generator. Plug it into the SAPC and wind up the revs and you can fine tune the power valves especially when running the programmable zeeltronic ecu.
Steve Bass said:
When I get back from my business trip I’ll post a picture of the engine stand I made for working on it. Makes life easier for setting up the barrels and head squish, power valves etc.
be careful to check the crank condition. I don’t think there’s any new ones left so rebuilding is the only option.
Barrels are not available so guard yours with your life!!!
Last time I checked with Sean, carb parts were still unavailable due to Covid but hopefully that’s changed. I need to change my jetting from the Johannesburg altitude to the Ontario sea level and humidity.
Something else that was incredibly useful for setting up the engine is an rpm generator. Plug it into the SAPC and wind up the revs and you can fine tune the power valves especially when running the programmable zeeltronic ecu.
Bought a new crank for mine 5 years ago from Robinson's foundry, they had a 20% off everything in a Black Friday sale, paid around £550 for it. Just checked their website and they appear available to order, but nearly a grand now....be careful to check the crank condition. I don’t think there’s any new ones left so rebuilding is the only option.
Barrels are not available so guard yours with your life!!!
Last time I checked with Sean, carb parts were still unavailable due to Covid but hopefully that’s changed. I need to change my jetting from the Johannesburg altitude to the Ontario sea level and humidity.
Something else that was incredibly useful for setting up the engine is an rpm generator. Plug it into the SAPC and wind up the revs and you can fine tune the power valves especially when running the programmable zeeltronic ecu.
Another option for the Suzuki parts side of things is buying them from is Web!ke Japan - https://japan.webike.net/SUZUKI/RGV250+Gamma/592/m...
You'll have to work out the part numbers from somewhere else (eg fowlers) but they can be *much* cheaper to buy parts even when you take into account including the shipping from Japan and import duty.
For an example my VFR has a bunch of little rubber washers, one behind each fairing bolt. They're £5ea from a UK Honda dealer but £1.34 each from Web!ke. So buying a set of 4 is about £10 cheaper with delivery included....but obviously takes a lot longer to get here!
You'll have to work out the part numbers from somewhere else (eg fowlers) but they can be *much* cheaper to buy parts even when you take into account including the shipping from Japan and import duty.
For an example my VFR has a bunch of little rubber washers, one behind each fairing bolt. They're £5ea from a UK Honda dealer but £1.34 each from Web!ke. So buying a set of 4 is about £10 cheaper with delivery included....but obviously takes a lot longer to get here!
Thanks all!
Steve, would like to see photos of the stand please, going to have a work friend weld something up to fit the rear mounts but would be interesting to see an idea.
All great on the parts, like I said I get a good Suzuki discount, well beyond any general trade pricing....
Hoping I can get someone to rebuild the crank using new Suzuki parts I supply to make it sensible - half tempted to give the crank a go as have v blocks and dial gauges plus a press but don't have the experience which can be essential!
Looks like cylinders are now made by Athena? If needed hoping mine can just be replated and again the trade price in the USA is cheaper than I can find anywhere in the uk.
Heads can then be aquablasted.
Don't plan on making any ignition changes so hopefully all the standard set up and using the manual for power valve set up should be good.
Steve, would like to see photos of the stand please, going to have a work friend weld something up to fit the rear mounts but would be interesting to see an idea.
All great on the parts, like I said I get a good Suzuki discount, well beyond any general trade pricing....
Hoping I can get someone to rebuild the crank using new Suzuki parts I supply to make it sensible - half tempted to give the crank a go as have v blocks and dial gauges plus a press but don't have the experience which can be essential!
Looks like cylinders are now made by Athena? If needed hoping mine can just be replated and again the trade price in the USA is cheaper than I can find anywhere in the uk.
Heads can then be aquablasted.
Don't plan on making any ignition changes so hopefully all the standard set up and using the manual for power valve set up should be good.
Thanks for the info on the stands, should be able to get something done easily.
Appreciate the info on the media tumbler - didn't realise they were available on a small scale, looking into that, not sure if they will need a paint or plating after though?
No progress last weekend, spent it at Silverstone with the Birkett and and 750mc Sunday but plan to have a long weekend this one.
Had a L of engine oil arrive, ordered head and base gaskets. Got some paddock stand bobbins a few other random o rings and seals.
Found a mega trade price on rods and pistons, with bearings and rings (£300!) which are Pro X brand - owned by Wiseco and reviews seem to be good. Hoping cylinders don't need replating so that immediate funds can go on something like suspension refresh.
Appreciate the info on the media tumbler - didn't realise they were available on a small scale, looking into that, not sure if they will need a paint or plating after though?
No progress last weekend, spent it at Silverstone with the Birkett and and 750mc Sunday but plan to have a long weekend this one.
Had a L of engine oil arrive, ordered head and base gaskets. Got some paddock stand bobbins a few other random o rings and seals.
Found a mega trade price on rods and pistons, with bearings and rings (£300!) which are Pro X brand - owned by Wiseco and reviews seem to be good. Hoping cylinders don't need replating so that immediate funds can go on something like suspension refresh.
Few hours on it today so made some progress on the strip down.
Overall still very happy, under the dirt/mould it is a very clean bike.
Rest of the cooling system off tomorrow, along with the exhaust and then the engine will come out. Really hoping the bores are ok on it then it will be mainly replacing corroded bolts and clips etc. Radiator looks great.
Have noted a large amount of play on the power valve pullies, not sure if this is normal of not but will get more of an idea once its apart.
Overall still very happy, under the dirt/mould it is a very clean bike.
Rest of the cooling system off tomorrow, along with the exhaust and then the engine will come out. Really hoping the bores are ok on it then it will be mainly replacing corroded bolts and clips etc. Radiator looks great.
Have noted a large amount of play on the power valve pullies, not sure if this is normal of not but will get more of an idea once its apart.
MK3 Dan said:
Have noted a large amount of play on the power valve pullies, not sure if this is normal of not but will get more of an idea once its apart.
The pulleys do wobble around a bit, they need the free play to operate smoothly.It's all sprung loaded so you can't over travel the valves .
Bit hard to explain how they work, get a manual and take them apart to understand them.
Eventually you will need to power up the PV control unit to check the PV settings. (If its the same as the RGV)
Had another good few hours on it today and the engine is out:
Found a crack in the engine cradle but no other unexpected surprises:
Taking the engine into work next week so will get the top ends off and see what we are working with.
Will order up swingarm, suspension and head stock bearings this week so that I can remove them next weekend, clean everything, replace the bearings and reassemble.
Exhaust, Radiator and some little brackets off for Cerakote next week as well.
Found a crack in the engine cradle but no other unexpected surprises:
Taking the engine into work next week so will get the top ends off and see what we are working with.
Will order up swingarm, suspension and head stock bearings this week so that I can remove them next weekend, clean everything, replace the bearings and reassemble.
Exhaust, Radiator and some little brackets off for Cerakote next week as well.
Before you spend money on ceramic coating the exhausts, I would make sure that's s definitely the route you want to go down. If you have any inclination for tuning, the exhausts will be the first things to go.
I would hold fire, you're in no rush and if you decide to go the standard route it's an easy job at any point in the future even after a full rebuild.
I would hold fire, you're in no rush and if you decide to go the standard route it's an easy job at any point in the future even after a full rebuild.
Fantastic bikes the RS250, I got one in 2001 after my GSXR600 was nicked, used it for commuting into Canary Wharf and a few trips over to Le Mans.
After regular use it sat in the corner of the garage for a few years until 2018 (I think) a fella I got to know wanted to buy it. It hadn't run for a few years but once he'd paid the money he kicked it over and it started, albeit a bit lumpy.
Still keep in contact with him and once he'd had a carb clean out and rebuild it was running fine. Only bike to get more than i paid for it, that didn't factor in all the maintenance though.
Previous to the RS i'd had a couple of RGV250's, but always preferred the RS.
Good luck with it, great bikes.
After regular use it sat in the corner of the garage for a few years until 2018 (I think) a fella I got to know wanted to buy it. It hadn't run for a few years but once he'd paid the money he kicked it over and it started, albeit a bit lumpy.
Still keep in contact with him and once he'd had a carb clean out and rebuild it was running fine. Only bike to get more than i paid for it, that didn't factor in all the maintenance though.
Previous to the RS i'd had a couple of RGV250's, but always preferred the RS.
Good luck with it, great bikes.
xstian said:
Before you spend money on ceramic coating the exhausts, I would make sure that's s definitely the route you want to go down. If you have any inclination for tuning, the exhausts will be the first things to go.
I would hold fire, you're in no rush and if you decide to go the standard route it's an easy job at any point in the future even after a full rebuild.
I have gone for it, I get a good price on it along with some other parts and think if I was to sell them on or even keep to sell with it if I change having them Cerakoted will help.I would hold fire, you're in no rush and if you decide to go the standard route it's an easy job at any point in the future even after a full rebuild.
Will admit I’m surprised by the weight the of the OEM pipes, very heavy for what they are, would consider a change if you could get a lightweight version that doesn’t warrant a jetting change.
Gassing Station | Biker Banter | Top of Page | What's New | My Stuff