🏷️ Basic Information Identification Make: Aprilia Model: RS250 Year: 2003 Codes Vin Prefix: AP981 Engine Code Variant: RGV250-based V2 👋 Introduction Market Position Classification: High-performance sportbike Target Audience: Enthusiasts, track day riders, mechanics Competitive Analysis Key Competitors: Yamaha R6, Suzuki GSX-R600, Kawasaki ZX-6R (in its class, though a 250cc) Key Features Engine Technology: V-twin 2-stroke, reed valve induction, advanced exhaust powervalve system Chassis Design: Lightweight aluminum twin-spar frame, sophisticated suspension components Braking System: Dual front disc brakes with radial-mount calipers (on later models) 📋 Manual Details Coverage Areas Primary Coverage: Complete Factory Service Repair Secondary Coverage: Maintenance, Diagnostics, Repair, Overhaul Page Count Estimated Pages: 400+ Manual Type Type: Factory Service Repair Manual Language Language: English Format Format: Downloadable PDF 📖 Manual Coverage Systems Covered Engine: 2-stroke V-twin, carburetion, lubrication, cooling, exhaust Transmission: 6-speed sequential, clutch, gearbox overhaul, lubrication Chassis: Frame inspection, suspension (front forks, rear shock), steering assembly Brakes: Front and rear hydraulic disc brakes, master cylinders, calipers, fluid specifications Electrical: Ignition system, lighting, charging system, battery, wiring diagrams, ECU troubleshooting Fuel System: Carburetor tuning (Mikuni TMX), fuel lines, fuel tank Bodywork: Fairings, seat, fuel tank, fenders, removal and installation procedures Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, spark plug checks, chain adjustment Troubleshooting: Diagnostic flowcharts for common issues, electrical faults, engine performance problems Repair: Engine rebuild, transmission repair, suspension overhaul, brake caliper service, electrical component replacement Component Disassembly: Step-by-step instructions for disassembling and reassembling all major components Technical Depth Depth: Comprehensive (from basic adjustments to full engine rebuilds) Diagnostic Focus: Detailed fault finding and diagnostic procedures Torque Specifications: All critical fastener torque values provided Clearances: Engine component clearances (piston, rings, crankshaft) and chassis tolerances 📊 Manual Specifications File Format Format Details: High-resolution, searchable PDF document Print Quality Quality: Printable at original factory quality Binding Type Binding: N/A (Downloadable PDF) Paper Type Paper: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 2-stroke, V-twin Displacement: 249 cc Bore X Stroke: 54 x 54.5 mm Compression Ratio: 7.4:1 Reed Valve System: Yes Powervalve System: APRCS (Aprilia Racing Control System) exhaust powervalve Performance Horsepower Claimed: Approx. 70 HP @ 11,750 rpm (depending on region and tuning) Torque Claimed: Approx. 4.5 kgm (32.5 lb-ft) @ 10,000 rpm Fuel System Carburetors: 2 x Mikuni TMX30 Flat Slide Fuel Type: Unleaded Gasoline (95 Octane or higher recommended) Oil Mixture: Automatic Oil Injection System (use 2-stroke synthetic oil) 🔧 Transmission Standard Type: 6-speed, constant mesh, sequential return Clutch: Wet, multi-plate, cable-actuated Features Gear Ratios: Detailed ratios provided in manual Final Drive: Chain drive (520 pitch recommended) 📐 Dimensions Exterior Length: Approx. 1990 mm Width: Approx. 710 mm Height: Approx. 1130 mm Weights Dry Weight: Approx. 140 kg Wet Weight: Approx. 155 kg (with fluids) Weight Distribution: Optimized for sportbike handling 🛡️ Safety Features Ratings Crash Test Ratings: N/A (Motorcycle specific, not applicable) Active Features Braking: Dual front discs, single rear disc, braided brake lines (later models) Suspension: Adjustable front forks (preload, compression, rebound), adjustable rear monoshock Passive Features Frame: Sturdy aluminum twin-spar frame for rigidity Rider Ergonomics: Sport-oriented rider position, well-placed controls 💡 Technology Features Infotainment System: N/A (Focus on performance, no infotainment system) Driver Assistance Features: N/A (Focus on rider control, no electronic rider aids like ABS or traction control) 🔧 Maintenance Service Intervals Oil Change: Refer to manual for specific mileage/time intervals (typically every 3,000-5,000 km) Spark Plug Inspection: Refer to manual (e.g., every 5,000 km) Chain Lubrication Adjustment: Regular intervals, as per manual recommendations (e.g., every 500-1000 km) Major Engine Overhaul: Refer to manual (depends heavily on usage, often 15,000-20,000 km for optimal performance) Fluid Specifications Engine Oil Type: High-quality 2-stroke synthetic oil (e.g., Motul 800, Castrol TTS) Coolant Type: Ethylene glycol-based antifreeze mixture (50/50 water/coolant) Brake Fluid Type: DOT 4 recommended Transmission Oil Type: Refer to manual (typically a specific gear oil or engine oil for the gearbox) Known Issues Powervalve Sticking: Common on 2-strokes due to carbon buildup; requires regular cleaning and lubrication. Carburetor Sync And Tuning: Crucial for smooth running; requires specialized tools for accurate synchronization. Clutch Wear: Can wear faster with aggressive riding; proper adjustment and fluid are key. Ignition System Components: CDI units and coils can be prone to failure with age; diagnostic procedures are vital. 📚 Vehicle History Brand Heritage Manufacturer Origins: Italian manufacturer with a strong racing pedigree in Grand Prix motorcycles Model Evolution Development Basis: Derived from the highly successful Suzuki RGV250 platform, with Aprilia chassis and styling enhancements Previous Generations: Previous RS250 models featured different styling and componentry Production Production Period: 1995-2003 Manufacturing Location: Italy 🏆 Awards & Recognition Recognitions Performance Acclaim: Widely recognized for its sharp handling, strong mid-range power delivery for a 250cc, and racing pedigree. Ratings Magazine Reviews: Consistently praised by motorcycle publications for its track capability and exciting character. Certifications Emissions Compliance: Manual will cover emissions-related...