HYBRID ENGINE MOUNTING CRADLE KIT APRILIA RS250 FRAME / RZ/BANSHEE ENGINE Thank you for your purchase of the Hybrid Engine Mounting Cradle Kit. It is designed to allow you to mount any version of the Yamaha RZ350 or Banshee engines into the Aprilia RS250 frame. These instructions will guide you through the process of mounting the kit and explain the function of all of the parts included in the kit.
Bill of Materials Item Name Description Qty 97-0310 Hybrid Engine Torsion Bar Kit 1 97-0400 Hybrid Rear Shocker Rocker Arm Assembly 1 02-0030 Nylon Insert Hex Nut - M10(1.5 pitch) 2 02-0526 Hybrid Rear Motor Mount Bolt Bushings 1 02-0525 SHCS M6(1.0)x100mm Stainless Steel 1 97-0360 Hybrid Cradle Arms - Set 1 02-0523 Rear Engine Mount 1 Aluminum 1 02-0524 Rear Engine Mount 2 Aluminum 1 02-0106 Connecting Rod - 270mm Long M6 RH Thread 1 01-0082 U Shape Shift Shaft for XX-0096 1 99-0007 Offset (18.6mm) Sprocket 18 Tooth 520 Chain 1 02-0509 Rod End M6 RH Thread for 6mm pin 2 02-0532 SHCS M8 x 35mm Stainless 4 02-0045 Nylon Insert Nut - M8 x 1.25 Pitch 4 02-0533 Hybrid Front Motor Mount Threaded Rod 1 02-0534 Hybrid Front Short Motor Mount Spacer 1 02-0535 Hybrid Front Motor Mount Long Spacer 1 02-0536 Hybrid Front Mount Washer 3.5mm 2 02-0537 Hybrid Front Mount Washer 1mm 2
Please review the Bill of Materials listed above as well as the pictures and make sure you have received all parts listed when your kit arrives. All claims for missing parts MUST be received within 30 days after you receive your kit. No claims will be honored after 30 days. ASSEMBLY To begin assembly a stripped Aprilia RS250 frame (all parts removed) and a set of RZ350 or Banshee cases also stripped of all parts are needed. First step is to mount the cradle arms to the front motor mount as shown in the picture below:
Note the order of assembly aluminum bushings on the outside and steel washers on the inside against the case mounts. Steel washers are needed against the Yamaha mounts to avoid gouging. We also provide 2 additional 1mm thick steel washers to use for shimming if needed as there are variations between frames and cases. You will note that one end of the front motor mount bolt has an internal hex on one end as shown below: Using a hex key this allows you to hold it still while tightening both nuts. The next step involves mounting new rear engine mounts to the RS250 frame. First step will be to remove the existing rear mounts by carefully cutting and then sanding the surface for a smooth round surface. We recommend a professional with experience perform this step. This picture shows the before and after:
This picture shows the existing rear motor mounts and the new location for the new rear motor mounts: Using the 2 new billet rear mounts and the rear motor bolt assembly shown here: Install both to the rear motor mount on the cases as shown here:
Now turn the Aprilia frame upside down and mount the cases you have assembled with cradle arms to the frame. Carefully position the cases as shown here:
The motor mount with the notch for clearance is closest to the side frame. Carefully check the alignment of the cases with the frame to be sure the cases are square and parallel with the frame. Check it twice to be sure. At this point we are ready to weld the new rear engine mounts to the frame. We highly recommend that TIG welding is used and that it is done by a certified professional welder. Now we are ready to reassemble the Hybrid. The torsion bar kit will be used from the rear frame mounts to the bottom of the engine cases as shown here:
Your kit also contains a new, narrower shock rocker arm and stainless steel dogbones to replace the stock Aprilia items. This allows you to run expansion chambers with a larger diameter center body that will better suit the RZ350/ Banshee based engine you will be using: In addition your kit includes a new shift rod with rod ends as well as a new shift arm designed to work with this cradle kit as shown here:
This picture also shows the 18.6mm offset sprocket provided that allows the use of a 160 section rear tire with the new frame/engine combination. DISCLAIMER This cradle kit is intended for off highway use ONLY. It has not been certified for highway use in any country in the world and is intended for racing or track days ONLY. Fast from the Past, Inc. will take no responsibility for any other use of any kind. Due to the intended use there is no warranty express or implied for this product. Purchaser agrees by purchase and use of this kit to take all responsibility for any and all problems created by us of this cradle kit.