Aprilia RS250 1999 Mugello Replica

  • Hello

    i will start this project slowly , no hurry's, i cant drive this beast yet, need to be 24 years old to take the licence. only in january i can have the licence.

    i will post the photos of the beginning of this build, and i will explain my objectives with this bike.

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    First Parts will be:

    • USED OEM Brembo discs x2, bought here in portugal for 120€ pretty good, insted of paying 500€ for brand new discs

    • New BREMBO front master cylinder RCS19 with TWM clutch. (Same like i did on RS125, but 19 instead of 15) (~330€)

    • New/Used Genuine Complete Headlight from RS125 (90-05) or RS250 since they use the same light

    • New/Used complete back light with licence holder from RS125 (90-05) or RS250 since they use the same

    • New Genuine Windshield (~90€) already bought on eBay.

    after this basic stuff, i will buy new tyres, new exhaust ( i like loud bikes :D) Tyga or JimLomas Side by Side with carbon silencers. this cost around 1.000€

    Work needed on the bike:

    • New paint in Mugello Colours with stickers. ( i already have most of the stickers needed, since i bought for my rs125 some time ago, but they were very hard to fit on rs125 late models)
    • Need to remove the paint insome parts (calipers, handlebars, wheels) previous owner did a bad job painting them.

    for now, this are the most important things to fix for me.

    If you guys know someone that have OEM parts that i need, i will aprecciate

    Thanks for all your help in the previous build, in special @Calum and @NINJA

    P.S. Sorry for my english, not my native language

  • @pedrobatista10 Apart from the black wheels I like the colour scheme as it is - classic racing Aprilia. With those upgrades she will be singing perfectly in tune very soon. Having to wait 6+ months will give you the time to build her to your dream spec.

    I do not know of any Spanish Aprilia dealers, but I'm sure that there must be some. In the UK these are the 3 main Aprilia parts suppliers, all will ship to the EU Nps;




    For upgrade parts then I would suggest either of these two;



    Keep us updated with your new 'Beastie' !!! :grinning_face_with_smiling_eyes: :face_with_stuck-out_tongue_winking_eye: :grinning_face_with_smiling_eyes:

  • Yes mate this is fabulous!

    I am wet with envy.

  • @Calum Shouldn't that be 'Hard' with envy? As in 'women' get wet??? :winking_face: :winking_face: :smiling_face_with_open_mouth_cold_sweat: :face_with_tears_of_joy: 🤣

  • @NINJA it’s 2019 you can’t make assumptions of gender on the internet anymore

  • @declan :grinning_face_with_smiling_eyes: :smiling_face_with_open_mouth_closed_eyes: :smiling_face_with_open_mouth_cold_sweat: :face_with_tears_of_joy: 🤣 🤣 🤣

  • @NINJA I didn't think I had to specify this. But I have gone past the point of being hard to jizzing in my pants and now I am wet.

  • @Calum There's also wetting the bed.................................... 😉

  • @Calum gross

  • Hi guys,

    i will need some help to find some parts, im checking ebay and lebocoin everyday, but till now no sucess

    1- ~~Driver Seat OEM for RS250 1998-2003

    2- Low.rear fairing lockup - AP8138893

    3 - Saddle support cover - AP8139785

    for now this 3 parts are the most important for me to start the project

    if you know something, hit me up please

    thanks guys!

  • @NINJA OMG, thank you! I already found all parts i need from a guy on the group, except the seat.

    And for a very good price

  • hi

    when i say it will be mugello replica, it need to be complete. the rider must have the right equipment 😄

    hope you like, it was custom made with AGV k3 helmet, done by Adriano Versa (Italian Designer of helmets, bikes, etc )

    the worst thing about original replicas, is that they are really old helmets, they look better ofc. but they have a lifetime of 5 years, after that it compromise our safety. that way i prefered to make a custom replica in a brand new helmet.

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  • @pedrobatista10 Now that is being a true fan for-sure!!! :grinning_face_with_smiling_eyes: :face_with_stuck-out_tongue_winking_eye: :grinning_face_with_smiling_eyes:

  • Hi guys

    quick update on the parts that i already found and bought.

    Used OEM Brembo discs x2

    Used Genuine Complete Headlight

    Used complete back light with licence holder

    New Genuine Windshield

    Used driver seat

    Used Low rear fairing lockup

    thanks to @NINJA for the facebook group's , found almost every part used there.

    Next month, i hope i can order this parts:

    Brembo RCS 17 with the TWM clutch( some guys told me better then rcs19 for rs250) and Brembo Rear Disc

    i cant buy much more parts for now, unfortunately i damaged the engine of my pitbike. and will not be cheap to repair i guess 😞

  • hi

    yesterday i started to remove parts from the rs, to send to the powder coating. i want to remove the wheels too , but i need a stand to keep the bike straight. i already have one that i use for the rs125, but i need one for the front, so that way i can remove both wheels without problems. any suggestion?

    btw, im doing pretty fine removing parts from a bike for the first time. but i'm struggling with some bolts and nuts that are very hard to remove. for example on both front brembo calipers i cant remove the nut that connects the braking cable.

    i think i need some more tools to have at my home. once again, i accept suggestion for tools

  • i was bored at home, and i said to myself that i can remove the engine of the bike and save some cash not paying to someone to do it for me.

    so i did

    looks very dirt inside
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    out of the frame already
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    i may be wrong but i think this engine never left the frame of the bike in 20 years 😄
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    look the powevalve housing, this after a cleaning with absorvent paper. when i opened lots of burned oil leaked
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    piston, i dont have a clue if its very bad condition or not. what you guys think?
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    cylinder head, no ideia again if bad or not
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    what's your opinions? full rebuild since i have engine out? btw, the engine i will not touch, no skills for that.

    this was the first time i worked on a bike, im proud of myself that i did it. i organized all parts and screws on zip bags to not lose anything.

    hope you like it!

  • Hey looking smart.

    I mean, it's out now, may as well rebuild it yourself.

    I dunno, depends whether you want it rebuilt or not. What's the mileage? These types of bikes tend to be owned by more mature owners so don't tend to need to rebuilding as often.

    At worst, I'd throw a set of rings in there. They actually say not to clean the carbon off the piston as it retains the heat and allows the gases to propagate faster = more power. Well there goes the theory.

    The head should be polished to a mirror sheen though.

    Looking good though.

  • @Calum 15.000 km i think, its estimated time for a change of pistons i guess.

    i would love to rebuild it myself, but i will not risk this engine. first i need to learn on dtx and rs 125 then i will adventure on this beast.

    i think i will replace everything, pistons, pv's, pulleys, water inlets , basically make a complety fresh engine. then i will know what to expect from the engine.

    i will take more time to make it running but i have more insurance that it dont break so easily.

    btw, what products you guys use to clean engine, carbs and general parts? i heard brake cleaner is good, but want to know what you use first.

  • @pedrobatista10 You can clean most things with Carb cleaner, which is not too abrasive. 😉