🏷️ Basic Information Identification Make: Aprilia Model: RS250 Year: 1996 Product Type: Full Service Repair Manual 👋 Introduction Market Position Market Segment: Lightweight, high-performance sportbike Competitive Analysis Competitors: Yamaha YZF-R6, Suzuki GSX-R600, Kawasaki Ninja ZX-6R, Ducati 750SS Key Features Design Philosophy: Race-derived technology, aggressive styling, potent 2-stroke performance Engine Type: V-twin, 2-stroke, liquid-cooled Performance Focus: Strong power delivery in the mid-to-high RPM range 📋 Manual Details Coverage Areas Manual Scope: Comprehensive repair, maintenance, rebuilding, refurbishment, and restoration Model Variants Covered: All Aprilia RS250 models from 1996, encompassing any minor variations or updates within that year. Page Count Estimated Page Count: 300+ Manual Type Type: Service and Repair Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Engine: 2-stroke V-twin, top-end rebuilds, bottom-end assembly, lubrication, cooling system Fuel System: Carburetor tuning (Dell'Orto PHBH 28), fuel pump, fuel lines, tank maintenance Ignition System: CDI ignition, spark plug selection and gap, coil testing, wiring diagrams Exhaust System: Expansion chamber maintenance, sealing, power valve operation and adjustment Transmission: 6-speed gearbox, clutch assembly, gear ratios, lubrication, shift mechanism Suspension: Front forks (Showa upside-down), rear monoshock (Öhlins optional), fork oil levels and types, shock absorber service Brakes: Front dual disc (Brembo calipers), rear single disc, brake fluid types and bleeding procedures, caliper overhaul Electrical System: Wiring diagrams, battery maintenance, charging system, lighting, instrumentation, starter motor Chassis And Frame: Frame inspection, steering head bearing service, swingarm pivot service Bodywork: Fairing removal and installation, seat, fuel tank, fenders Procedures Included Maintenance: Regular servicing, oil changes, filter replacements, chain adjustment, brake pad replacement, coolant checks Troubleshooting: Diagnostic flowcharts for common issues, electrical fault finding, engine performance problems Repair: Complete disassembly and reassembly instructions for all major components Rebuilding: Engine internal component rebuilding (pistons, rings, crankshaft), gearbox rebuilds Electrical Troubleshooting: Detailed wiring diagrams and fault diagnosis for electrical systems. Suspension Adjustment: Guidance on setting sag, damping, and rebound for both front and rear suspension. Technical Depth Depth: In-depth technical guidance suitable for experienced mechanics and dedicated enthusiasts Rebuild Procedures: Step-by-step instructions for complete engine and gearbox rebuilds. 📊 Manual Specifications File Format Quality: High-resolution scans, clear text, searchable content Print Quality Print Readability: Excellent readability for printing individual pages Binding Type Binding: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Code: MK1 V990 / MK2 V990 Engine Type: Liquid-cooled, 90-degree V-twin, 2-stroke Displacement: 249 cc (249.3cc) Bore X Stroke: 54 mm x 54.5 mm Compression Ratio: 7.5:1 (approx.) Performance Horsepower: 70 HP @ 11,000 RPM (claimed) Torque: 4.0 kgm @ 10,000 RPM (claimed) Fuel System Carburetors: 2 x Dell'Orto PHBH 28 RD Fuel Delivery: Separate oil injection (Oil Master system) Fuel Type: Unleaded 98 RON recommended Lubrication Oil Type: 2-stroke synthetic blend for oil injection 🔧 Transmission Standard Type: 6-speed constant mesh Features Clutch: Wet, multi-plate, cable-actuated Gear Ratios: Refer to manual for specific ratios (e.g., 1st: 2.500, 2nd: 1.778, 3rd: 1.400, 4th: 1.188, 5th: 1.042, 6th: 0.958) Final Drive: Chain drive, 520 pitch 📐 Dimensions Exterior Length: Approx. 1980 mm Width: Approx. 720 mm Height: Approx. 1135 mm Wheelbase: Approx. 1380 mm Weights Dry Weight: Approx. 142 kg Wet Weight: Approx. 158 kg (with fluids) Fuel Tank Capacity: 16 Liters 🛡️ Safety Features Ratings Crash Test Data: N/A (Motorcycle) Active Features Braking System: Dual front hydraulic disc brakes, single rear hydraulic disc brake Passive Features Lighting: Halogen headlamp, LED tail light, turn signals 💡 Technology Features Infotainment Infotainment System: N/A (Basic analog instrumentation) Instrumentation Dashboard: Analog speedometer, tachometer, coolant temperature gauge, basic warning lights. 🔧 Maintenance Service Intervals Oil Change Engine: Refer to manual; typically every 3,000 km or annually. Spark Plug Replacement: Refer to manual; typically every 6,000 km. Chain Lubrication Adjustment: Every 500 km or after washing/rain. Air Filter Cleaning: Refer to manual; typically every 6,000 km. Fluid Specifications Coolant Type: Ethylene glycol-based coolant with corrosion inhibitors (50% mixture with distilled water) Brake Fluid Type: DOT 4 Transmission Oil Type: SAE 75W/90 or SAE 80W/90 API GL-4 gear oil Fork Oil Type: Refer to manual for specific viscosity and level (e.g., Showa SS-03 or equivalent) Known Issues Power Valve Sticking: Common due to carbon buildup; requires regular cleaning. Crankshaft Seals: Can degrade over time, leading to air leaks and performance issues. Carburetor Synchronization: Requires periodic adjustment for optimal performance. Oil Injection Pump Failure: Critical to maintain; pump failure leads to engine seizure. 📚 Vehicle History Brand Heritage Manufacturer: Aprilia is an Italian manufacturer known for its performance motorcycles, particularly in racing. Model Evolution Heritage Connection: The RS250 is directly derived from Aprilia's Grand Prix racing technology, utilizing a Suzuki RG500 Gamma derived engine. Production Production Years: 1995 - 2003 Manufacturing Location: Italy 🏆 Awards & Recognition Recognitions Performance Accolades: Highly regarded for its performance and handling in its class during its production era. Ratings Expert...