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Athena presents the new cylinder kit for Aprilia RS250 and Suzuki RGV 250

3 October 2023

Alonte (VI), Italy, September 2023. Athena - leader in the highperformance motorcycle, scooter and moped spare parts market for 50 years- presents the brand new Cylinder Kit for Aprilia RS 250 e Suzuki RGV 250.

The long experience acquired in the world of Racing allowed the Athena R&D Department to create a unique product on the market: a Standard Bore cylinder replacement kit for the original Aprilia-Suzuki, fully compliant with the OEM specifications and installable without making any modifications to the motorcycle crankcase.

The kit is composed of an aluminum cylinder, a flat-top piston, and all the specific gaskets to ensure optimal sealing and thus achieve maximum performance.



The cylinder, made of aluminum alloy, is ready for installation. The kit includes the oil mixer inlet fitting and the brass bushing for the exhaust valve shaft, both pre-assembled.

The cylinder wall is finished with a galvanic treatment and a Motor-Nicksil coating developed by the Athena R&D department, to ensure smoother sliding of the piston, less friction, and reduced wear of the piston rings.

To overcome the corrosion issue affecting the original Aprilia- Suzuki sleeve, Athena engineers have created a new brass sleeve that can be screwed directly into the cylinder.

The cylinder head stud seats have also been redesigned, and unlike the original, they are no longer in communication with the water passages of the cylinder. Finally, the inner diameter of the CNC-machined exhaust crossbar eliminates the risk of excessive expansion that could damage the piston.



The Athena flat-top piston kit was designed and developed specifically to maximize the high-performance of this cylinder kit. We selected a high silicon-content aluminum alloy to ensure a low coefficient of thermal expansion, and consequently, much tighter mating tolerances between piston and cylinder.

The lightweight piston skirt and the Molybdenum Disulfide coating ensure effective friction reduction, improving smoothness and durability. Additionally, the CNC-machined window on the intake side is designed to maximize lubrication for the needle roller cage bearing and the connecting rod small end shims.

The biconical piston pin is made of a nitride-treated aeronautical steel alloy and the rings included are Made in Japan and crafted from special steel with chromium nitride coating to ensure high hardness and low friction.



The gasket kit includes all the gaskets necessary for installing the cylinder kit and is fully compatible with the original Aprilia-Suzuki components.

The materials used and the manufacturing technologies make them particularly resistant to oils, fuels, mixtures of water with antifreeze and anti-corrosion: in particular, the head gasket and the cylinder base gasket have been redesigned using an innovative reinforced graphite material to ensure excellent adaptability to surfaces and uniform sealing over the entire surface.

The sealing is further improved through the application of a silicone bead sealing applied using high-precision screen printing machines and a special surface finishing treatment.

The Athena cylinder kit for Aprilia RS 250 and Suzuki RGV 250 is available at a suggested retail price of €699.99 (VAT included).

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