🏷️ Basic Information Identification Make: Aprilia Model: RS250 Year Range: 1994-1998 Vehicle Type: Sportbike Motorcycle Codes Chassis Codes: RS250 (MK I / MK II) 👋 Introduction Market Position Historical Segment: Performance-oriented sportbike, competing with other 250cc two-stroke and early 400cc four-stroke machines of its era. Competitive Analysis Key Competitors: Yamaha YZF-R25 (later models), Kawasaki Ninja ZX-2R, Honda CBR250RR, Suzuki RG250 Gamma (earlier). Key Features Distinctive Attributes: Derived from Grand Prix racing technology (Suzuki RGV250 Gamma chassis and engine architecture), lightweight, potent two-stroke performance, sharp handling, iconic styling. 📋 Manual Details Coverage Areas Manual Coverage Scope: Comprehensive service, repair, and maintenance for Aprilia RS250 motorcycles from 1994-1998. Page Count Estimated Page Count: 500+ Manual Type Manual Type: Workshop Repair Manual / Service Manual Language Language: English Format Digital Format: Downloadable (PC, MAC, Tablets, Smartphones) 📖 Manual Coverage Systems Covered Engine System: 2-stroke V-twin engine, cooling system, lubrication system, ignition system, fuel injection/carburetion (depending on market variant), exhaust system. Chassis System: Frame, suspension (front forks, rear shock absorber), steering system, wheels, tires. Braking System: Front and rear disc brakes, brake calipers, master cylinders, brake lines, brake fluid specifications. Electrical System Electrical Components: Wiring diagrams, battery, starter motor, alternator, lighting, sensors, ECU (if applicable). Bodywork And Fairings Fairing And Body Panels: Removal, installation, and repair of fairings, seat, fuel tank, fenders. Procedures Included Maintenance Procedures: Routine servicing, oil changes, filter replacements, chain adjustment, spark plug inspection and replacement, air filter cleaning/replacement. Repair Procedures: Engine disassembly and reassembly, carburetor/fuel system tuning, clutch service, transmission inspection and repair, suspension overhaul, brake caliper overhaul, electrical system troubleshooting and repair. Troubleshooting Guides: Diagnostic procedures for common issues, fault code interpretation (if applicable), step-by-step problem-solving. Technical Depth Depth Of Information: In-depth, professional-level detail suitable for experienced mechanics and serious DIY enthusiasts. Covers full rebuilds and complex diagnostics. 📊 Manual Specifications File Format File Type: PDF (likely, optimized for digital devices) Print Quality Image Resolution: High-resolution, clear diagrams and photos. Binding Type Binding Method: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 70-degree V-twin, 2-stroke Displacement: 249 cc Bore X Stroke: 54.0 mm x 54.5 mm Compression Ratio: 7.1:1 Valve Mechanism: Reed valve induction, Suzuki's Exhaust Control Valve (SECV) system. Performance Horsepower Output: ~70 hp (10,000 rpm) (approximate, varies by market regulation) Torque Output: ~38 Nm (9,000 rpm) (approximate, varies by market regulation) Fuel System Carburetion: Twin Mikuni TMR32 flat-slide carburetors (typically). Fuel Type: Unleaded gasoline (min. 95 RON recommended) Oil System: Premix oil injection system (Autolube). 🔧 Transmission Standard Transmission Type: 6-speed constant mesh, sequential manual Features Clutch Type: Wet, multi-plate clutch Final Drive: Chain drive 📐 Dimensions Exterior Length: ~2020 mm Width: ~710 mm Height: ~1120 mm Wheelbase: ~1390 mm Weights Dry Weight: ~130 kg Wet Weight: ~145 kg (approximate) Fuel Tank Capacity: 16 Liters 🛡️ Safety Features Ratings Safety Ratings: N/A (Motorcycle safety is typically assessed by individual tests rather than standardized ratings). Active Features Braking System: Dual front discs with 4-piston calipers, single rear disc with 2-piston caliper. Excellent stopping power for its class. Passive Features Chassis Design: Twin-spar aluminum frame for rigidity and stability, race-derived ergonomics. 💡 Technology Features Infotainment Infotainment System: N/A (Basic analog instrumentation: speedometer, tachometer, temperature gauge, indicator lights). 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,000-5,000 km or annually (refer to manual for specifics). Spark Plug Replacement: Every 6,000-10,000 km (NGK specifications usually required). Air Filter Cleaning: Every 3,000-6,000 km (depends on operating conditions). Chain Maintenance: Lubricate and adjust every 500-1,000 km, replace as needed. Fluid Specifications Engine Oil: High-quality 2-stroke synthetic oil for premix (e.g., Motul 800 2T, Castrol TTS). Coolant Type: Ethylene glycol-based antifreeze coolant (50/50 mix with distilled water). Brake Fluid: DOT 4 specification. Transmission Oil: API GL-4 SAE 80W/90 gear oil (capacity ~0.8 Liters). Known Issues Common Problems: Carburetor jetting sensitivity, wear on powervalve mechanisms, crank seal leaks, clutch wear, potential for piston/cylinder wear if not maintained properly, electrical connector corrosion. 📚 Vehicle History Brand Heritage Aprilia Legacy: Aprilia has a strong racing heritage, particularly in the 125cc and 250cc Grand Prix classes, which heavily influenced the RS250's design and performance. Model Evolution Rs250 Generations: The RS250 was largely based on the Suzuki RGV250 Gamma (VJ22) platform, with Aprilia contributing its own chassis design and suspension tuning. Two main 'MK' generations existed, with subtle updates over its production run. Production Production Years: 1994-2003 (with the 1994-1998 range covered by this manual) Manufacturing Origin: Italy 🏆 Awards & Recognition Recognitions Industry Accolades: Highly regarded by enthusiasts for its handling, performance, and race-derived technology. Often praised in period motorcycle publications for its agility and sharp handling.