🏷️ Basic Information Identification Make: Aprilia Model: RS250 Year: 1995 Product Type: Workshop Repair Service Manual Codes Model Code: RS250 👋 Introduction Market Position Description: The Aprilia RS250 was a highly regarded, lightweight, two-stroke sportbike that dominated its class in the 1990s, known for its exceptional handling and potent performance derived from Suzuki RGV250 Gamma underpinnings. Competitive Analysis Competitors: Honda NSR250R, Yamaha TZR250, Kawasaki KR-1S. Key Features Handling: Renowned for its agile chassis and excellent feedback. Engine: V-twin, liquid-cooled, two-stroke engine offering exciting power delivery. Braking: Equipped with capable Brembo braking components. Design: Sporty, aggressive styling inspired by Aprilia's Grand Prix racing machines. 📋 Manual Details Coverage Areas Engine: Yes Transmission: Yes Chassis: Yes Electrical System: Yes Bodywork And Plastics: Yes Suspension: Yes Brakes: Yes Fuel System: Yes Cooling System: Yes Exhaust System: Yes Lubrication System: Yes Troubleshooting: Yes Maintenance: Yes Diagnostics: Yes Page Count Estimated Pages: 200+ Manual Type Type: Workshop Repair Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed breakdown, assembly, tuning, and component specifications. Engine Electrical: Ignition system, CDI unit, wiring diagrams, and troubleshooting. Carburetion: Mikuni TM34 flat-slide carburetor adjustment, synchronization, and overhaul. Cooling System: Radiator, water pump, hoses, and thermostat service. Lubrication System: Oil injection system, pump calibration, and maintenance. Exhaust System: Expansion chamber design, maintenance, and carbon buildup cleaning. Transmission And Clutch: Gearbox inspection, clutch service, gear ratios, and shift mechanism. Suspension Front: Telescopic fork (USD) service, oil levels, damping adjustments, and seal replacement. Suspension Rear: Monoshock absorber adjustment, linkage maintenance, and bearing service. Braking System: Front and rear brake caliper service, master cylinders, fluid replacement, and bleeding procedures. Wheels And Tires: Wheel bearing replacement, tire pressure, and mounting instructions. Electrical System Components: Battery, lighting, horn, indicators, and starter motor service. Frame And Bodywork: Frame inspection, fairing removal and installation, seat, fuel tank, and associated components. Procedures Included Routine Maintenance: Oil changes, filter replacements, chain adjustment, spark plug checks, and general inspections. Engine Rebuild: Top-end rebuild (cylinders, pistons, rings, head) and bottom-end overhaul (crankshaft, bearings). Carburetor Tuning: Detailed guidance on jetting, float levels, and idle speed adjustment for optimal performance. Suspension Setup: Instructions for adjusting damping and preload for different riding conditions. Brake Bleeding: Step-by-step process for bleeding hydraulic brake systems. Electrical Troubleshooting: Fault finding for common electrical issues using wiring diagrams. Fuel System Cleaning: Fuel line flushing and injector or carburetor cleaning. Wheel Bearing Replacement: Proper procedures for removing and installing wheel bearings. Fairing Removal Installation: Guidance on disassembling and reassembling body panels. Diagnostics And Fault Finding: Systematic approach to identifying and resolving mechanical and electrical problems. Technical Depth Depth: Comprehensive coverage from basic maintenance to full engine and chassis overhauls. Diagnostic Tools: Mentions required tools and specifications for accurate diagnostics. Tightening Torques: Includes precise torque specifications for all critical fasteners. Component Clearances: Provides specifications for piston-to-cylinder wall, ring end gap, and bearing clearances. Wiring Diagrams: Detailed, high-resolution wiring schematics for all electrical systems. 📊 Manual Specifications File Format Format: Searchable PDF Resolution: High-resolution for clear viewing and printing. Printability: Printable pages for workshop use. Print Quality Quality: N/A (Digital Format) Binding Type Type: N/A (Digital Format) Paper Type Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Type: Liquid-cooled, 90-degree V-twin, two-stroke Displacement: 249.2 cc Bore X Stroke: 54.0 mm x 54.5 mm Compression Ratio: 7.5:1 Ignition: Digital CDI Performance Horsepower: 70.0 HP @ 11,000 rpm Torque: 38.4 Nm (28.3 lb-ft) @ 10,500 rpm Fuel System Carburetor: 2 x Mikuni TM34SS flat-slide, dual throttle valves Fuel Induction: Reed valve induction Oil Delivery: Automatic oil injection 🔧 Transmission Standard Type: 6-speed constant mesh Clutch: Wet, multi-plate Features Gear Ratios: 1st: 2.500, 2nd: 1.875, 3rd: 1.444, 4th: 1.190, 5th: 1.000, 6th: 0.875 Final Drive: Chain, 520 pitch, 110 links (typical) 📐 Dimensions Exterior Length: 1970 mm (77.6 in) Width: 685 mm (27.0 in) Height: 1130 mm (44.5 in) Wheelbase: 1365 mm (53.7 in) Ground Clearance: 130 mm (5.1 in) Weights Dry Weight: 142 kg (313 lbs) Wet Weight: 162 kg (357 lbs) (estimated) Fuel Capacity: 16 Liters (4.2 US gal) Oil Tank Capacity: 1.3 Liters (0.34 US gal) 🛡️ Safety Features Ratings Crash Test Results: N/A (Motorcycle Specific) Active Features Braking System: Dual 320mm front discs with 4-piston calipers, single 240mm rear disc with 2-piston caliper. Suspension Damping: Adjustable front and rear suspension for stability. Passive Features Frame Construction: Aluminum twin-spar frame for rigidity and light weight. Lighting: Dual halogen headlights for improved visibility. 💡 Technology Features Infotainment System: N/A (Analog gauges: Speedometer, Tachometer, Temperature gauge, Neutral indicator, Turn signal indicators, High-beam indicator). Driver Assistance Features: N/A (Focus on rider input and machine feedback). 🔧 Maintenance Service Intervals Oil Change: Every 3,000-5,000 km (1,800-3,000 miles) or annually. Refer to manual for specific gearbox oil change interval. Spark Plugs: Inspect every 4,000 km (2,500 miles), replace as...