Aprilia RS250 Project
Discussion
I have just become the proud new owner of a MK2 RS250 project.
The bike was owned by a fiend who realised he is never going to do anything with it due to the pressures of family life.
It is a Jap import that has a Nova and had import paid but never registered.
Plan to go completely through it, engine top end as a min, clean and tidy plus new stickers (have been removed). Will try to keep this updated so as a minimum I have a log of my progress.
Looking forward to this one and something to do over winter!
Hoping to collect this weekend or next and then will get started on completely stripping it down.
Limited pictures of how it currently stands.
The bike was owned by a fiend who realised he is never going to do anything with it due to the pressures of family life.
It is a Jap import that has a Nova and had import paid but never registered.
Plan to go completely through it, engine top end as a min, clean and tidy plus new stickers (have been removed). Will try to keep this updated so as a minimum I have a log of my progress.
Looking forward to this one and something to do over winter!
Hoping to collect this weekend or next and then will get started on completely stripping it down.
Limited pictures of how it currently stands.
I had a 125 back in the day (I am not that old - 35!) and always wanted a 250 so looking forward to this.
Got it for a sensible price so once done up shouldn't loose too much money - depending how carried away I get.
I believe you have to split the cases for crank seals but was considering doing them, its now confirmed with that comment. I work for a company that rebuilds motorbike engines, although 4 stroke stuff, but means it have access to most of the tools required for a rebuild - along with an ultrasonic cleaner which should be good for the carbs. We also deal with Suzuki directly so maybe able to use some RGV engine parts for cost saving.
Also have contacts for paint, polishing, Cerakote etc so hoping to do this properly.
Have a friend with an RRV450 and I am looking forward to comparing them once done, hopefully in time for next summer.
Planning on collecting tomorrow afternoon so will be able to really see what I am dealing with.
Edited to add I should say 'looking forward' more in this post, I am just excited!
Got it for a sensible price so once done up shouldn't loose too much money - depending how carried away I get.
I believe you have to split the cases for crank seals but was considering doing them, its now confirmed with that comment. I work for a company that rebuilds motorbike engines, although 4 stroke stuff, but means it have access to most of the tools required for a rebuild - along with an ultrasonic cleaner which should be good for the carbs. We also deal with Suzuki directly so maybe able to use some RGV engine parts for cost saving.
Also have contacts for paint, polishing, Cerakote etc so hoping to do this properly.
Have a friend with an RRV450 and I am looking forward to comparing them once done, hopefully in time for next summer.
Planning on collecting tomorrow afternoon so will be able to really see what I am dealing with.
Edited to add I should say 'looking forward' more in this post, I am just excited!
Thanks for all the info so far guys and appreciate that Steve. Sleaford isnt a million miles from me so could be useful!
I agree with it being quite easy to work on from what I have experienced so far today.
Managed to get over and get it collected around midday:
Bodywork is marked up and the decals had been removed ready to sort it out - bonus that it came with a new set that I wasn't expecting. I also hadn't realised how close my friend had got to getting it sorted and on the road, it was running, it was MOT'd and insured and required the forms sending to
the DVLA. It was rejected and he worked out a later date that one chassis number was wrong on the NOVA (5 instead of an S) so had the importer resolve this but at that point life had got in the way.
It turns over on the kick start and feels like it has compression. Not even attempted to start it - I know the carbs will need work and it has no fuel in it. Plus the fuel tap is stuck in the on position.
Took the fairings off and it is obvious it has sat for a few years and not in the complete dry, think it was an old barn. Mould everywhere!
Battery was completely gone (0.4V!) so hooked up another just to see the mileage:
Committed to a steam clean (I know this is subject to opinion but I have never had an issue as long as drying it properly) and it has made a massive difference - under the dirt seems to be a very clean bike.
Overall I am really happy, I know the engine and carbs need sorting - although it was running fine when it went into storage and I have a friend who will sort the bodywork. Lots of little bits to do with odd rusty bolts etc and want to replace all the fuel and oil pipes with new but nothing should be particularly difficult.
Will be completely stripping it down next weekend and start on the engine plus getting the exhaust and a few other bits off for Cerakote.
I agree with it being quite easy to work on from what I have experienced so far today.
Managed to get over and get it collected around midday:
Bodywork is marked up and the decals had been removed ready to sort it out - bonus that it came with a new set that I wasn't expecting. I also hadn't realised how close my friend had got to getting it sorted and on the road, it was running, it was MOT'd and insured and required the forms sending to
the DVLA. It was rejected and he worked out a later date that one chassis number was wrong on the NOVA (5 instead of an S) so had the importer resolve this but at that point life had got in the way.
It turns over on the kick start and feels like it has compression. Not even attempted to start it - I know the carbs will need work and it has no fuel in it. Plus the fuel tap is stuck in the on position.
Took the fairings off and it is obvious it has sat for a few years and not in the complete dry, think it was an old barn. Mould everywhere!
Battery was completely gone (0.4V!) so hooked up another just to see the mileage:
Committed to a steam clean (I know this is subject to opinion but I have never had an issue as long as drying it properly) and it has made a massive difference - under the dirt seems to be a very clean bike.
Overall I am really happy, I know the engine and carbs need sorting - although it was running fine when it went into storage and I have a friend who will sort the bodywork. Lots of little bits to do with odd rusty bolts etc and want to replace all the fuel and oil pipes with new but nothing should be particularly difficult.
Will be completely stripping it down next weekend and start on the engine plus getting the exhaust and a few other bits off for Cerakote.
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.
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.
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.
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.
Twolane said:
Std RGV pipes are really heavy, they are double skinned with a mesh type layer inside.
Also interesting to find today that clip on's are very heavy. For a lightweight bike there does seem to be a mix of lightweight items and a few random heavy ones - guess some legislation or cost saving has been involved! Didnt get a chance over the weekend but had the day off today so spent a few hours on it.
Pretty much back to nothing now, annoyingly all the ring nut tools I had access too didn't fit the swingarm one so haven't been able to remove this - ordered one up and fingers crossed it will land for this weekend.
Also had the chain guide fall apart on me and they are no longer available - a quick google seems to suggest my only option is a Chinese one from eBay!
Nothing else to scary found, had one of the rear hugger bolts snap in the swingarm which is a pain but should be able to remove it. Some of the rear shock linkage had a couple of unhappy bolts so glad that I am stripping this down and replacing the bearings and regreasing.
Haven't investigated properly but think the rear caliper maybe seized as noted some wear on the inside of it and one piston out a lot further than another.
Borrowed an ultrasonic cleaner to do the carbs but surprised at how much it cleans other items, side by side for comparison on the front calipers (Will come apart and be done properly, this was just to test).
Hopefully the swing arm tool shows up for this weekend and I can complete cleaning it and getting new bearings in to start the rebuild. Need to get on the engine soon!
Pretty much back to nothing now, annoyingly all the ring nut tools I had access too didn't fit the swingarm one so haven't been able to remove this - ordered one up and fingers crossed it will land for this weekend.
Also had the chain guide fall apart on me and they are no longer available - a quick google seems to suggest my only option is a Chinese one from eBay!
Nothing else to scary found, had one of the rear hugger bolts snap in the swingarm which is a pain but should be able to remove it. Some of the rear shock linkage had a couple of unhappy bolts so glad that I am stripping this down and replacing the bearings and regreasing.
Haven't investigated properly but think the rear caliper maybe seized as noted some wear on the inside of it and one piston out a lot further than another.
Borrowed an ultrasonic cleaner to do the carbs but surprised at how much it cleans other items, side by side for comparison on the front calipers (Will come apart and be done properly, this was just to test).
Hopefully the swing arm tool shows up for this weekend and I can complete cleaning it and getting new bearings in to start the rebuild. Need to get on the engine soon!
Steve Bass said:
MK3 Dan said:
Steve Bass said:
I've got the full set of service manuals for the RS and the kit manuals for the RGV. shoot me a mail and I'll send them over if you want...
Thanks Steve, I have sent you a message.
stang65 said:
May be heavy on purpose to damp down vibration? Have you stripped them so you know what weight is due to the clip on, grip, end-weights etc. or is it the clip-on assembly that's heavy?
Completely stripped down for Cerakote so it is just the clip on itself. They are away now, I will weight it once back to see what it is.Birky_41 said:
What a great idea! Saving that pic and will do same with mine. Need to get top end done Dec/Jan time after I finish my GSXR
Was trying to find the best way to be able to access the lower power valve and upright was the best option.Just realised it was your videos I have been watching and making me look forward to getting this out on track, although your riding skills are well beyond mine!
Removed the cylinder heads and cylinders today. Was holding some hope as it apparently had been running and its only done 11,000 miles. Turns out that was false hope and the cylinders are not in great condition so will need replating.
Power valve on the lower cylinder also doesnt move correctly and the bushing has worn so the shaft moves around, more investigation is needed.
Getting the cylinders done will hold me up a little on the timescale and I may need to hold off slightly due to the budget and wanting to do the crank as well.
Power valve on the lower cylinder also doesnt move correctly and the bushing has worn so the shaft moves around, more investigation is needed.
Getting the cylinders done will hold me up a little on the timescale and I may need to hold off slightly due to the budget and wanting to do the crank as well.
Steve Bass said:
Ouch!!
Still, nothing a rebore and replate won't fix, along with shiny new pistons. In fairness, 11000 kms is about the service life of the motor for a top end refresh but in your case, go through it end to end. Take particular care with the throttle to oil pump calibration (easily dome and well described in the manual) and then use only decent quality oil. make sure it's an oil pump system compatible oil as the top oils are often premix only (motul for example)
Once you split the cases, take a good look at the LHS main bearing. it's very susceptible to wear if the oil pump is slightly out of calibration. Not sure new cranks are available anymore but they can be pressed and rebuilt. Sean at TTW is a good port of call...
And once it's built, invest in a simple phone driven miniature wand camera so you can look down into the bores periodically without popping the heads off..
welcome to RS250 ownership
That is what I am hoping for Steve, most cost effective for quality at the moment is to get onto Sean at TTW and see what he can do.Still, nothing a rebore and replate won't fix, along with shiny new pistons. In fairness, 11000 kms is about the service life of the motor for a top end refresh but in your case, go through it end to end. Take particular care with the throttle to oil pump calibration (easily dome and well described in the manual) and then use only decent quality oil. make sure it's an oil pump system compatible oil as the top oils are often premix only (motul for example)
Once you split the cases, take a good look at the LHS main bearing. it's very susceptible to wear if the oil pump is slightly out of calibration. Not sure new cranks are available anymore but they can be pressed and rebuilt. Sean at TTW is a good port of call...
And once it's built, invest in a simple phone driven miniature wand camera so you can look down into the bores periodically without popping the heads off..
welcome to RS250 ownership
Side note but see that Sean's website mentions him being airframes in the RAF, knew some people in the RAF when I was a teenager with RS's and I think they may have known Sean, plus my Dad was airframes in the RAF on Harriers!
Something does seem off with how bad this cylinder is and the fact the power valve is faulty. Oil fittings will be replaced and will be ran on Silkolene/Fuchs that is compatible. Have ordered a load of Tygon cheap but it is 2.4mm ID instead of the OEM 2mm so not sure if I can use this?
Suzuki still sell OEM cranks. I am very tempted, if i can sell mine for around £300 then it would cost my very little to fit a brand new one with our trade discount. Worth spending a little more to put brand new OEM in? Then replated cylinders and Pro X pistons wouldnt leave much to chance - other than me putting it together!
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