🏷️ Basic Information Identification Make: Aprilia Model: RS250 Model Year Range: 1994-1998 Product Name: APRILIA RS250 Service Repair Manual 1994-1998 👋 Introduction Market Position Motorcycle Segment: Lightweight two-stroke sportbike, known for its racing heritage and exhilarating performance. Competitive Analysis Key Competitors: Yamaha YZF-R6, Honda CBR600RR (later models), Suzuki GSX-R600 (later models), Kawasaki Ninja ZX-6R (later models). Key Features Performance Focus: Designed for track day performance and spirited street riding, emphasizing agility and power-to-weight ratio. Two Stroke Engine: Characteristic of its era, offering potent power delivery and a distinctive sound. Racing Derived Technology: Incorporates technologies and design elements from Aprilia's racing experience. 📋 Manual Details Coverage Areas All Repairs Covered: A-Z Models Covered: All Page Count Estimated Page Count: Extensive (typically 300+ pages for comprehensive manuals) Manual Type Manual Type: Service Repair Workshop Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine: Complete engine overhaul, top end, bottom end, lubrication, cooling, ignition, fuel delivery. Transmission: Gearbox disassembly, inspection, assembly, clutch operation, shift mechanism. Chassis And Suspension: Frame, swingarm, front fork (USD), rear shock absorber, steering system, bearings. Brakes: Front and rear brake system components, hydraulic lines, calipers, master cylinders, bleeding procedures. Electrical System: Wiring diagrams, lighting, battery, charging system, ignition system components, sensors, ECUs. Fuel System: Carburetor tuning and maintenance (likely Mikuni TMI 32), fuel tank, fuel lines. Exhaust System: Exhaust pipe, silencer (canister) maintenance and replacement. Bodywork And Fairings: Fairing removal and installation, body panel care. Procedures Included Scheduled Maintenance: Oil changes, filter replacements, chain adjustment, spark plug service, valve clearance checks (if applicable). Troubleshooting: Diagnostic procedures for common problems, fault finding charts. Engine Rebuild: Complete engine disassembly, inspection of internal components, reassembly instructions, torque specifications. Carburetor Rebuild: Detailed steps for carburetor disassembly, cleaning, reassembly, and adjustment. Suspension Servicing: Fork oil change, seal replacement, rear shock servicing. Brake System Overhaul: Complete brake system maintenance, including caliper rebuild and fluid flush. Electrical Diagnostics: Testing of ignition system, charging system, and other electrical components. Technical Depth Depth Of Information: Comprehensive workshop level, suitable for professional mechanics and experienced DIY enthusiasts. Detail Level: Detailed step-by-step instructions with accompanying diagrams and exploded views. Special Tools: Lists required special tools for specific repair procedures. 📊 Manual Specifications File Format File Format: Portable Document Format (PDF) Searchability: Likely text-searchable for quick information retrieval. Print Quality Print Quality: High resolution, suitable for printing individual pages or the entire manual. Binding Type Binding Type: Not Applicable (Digital Format) Paper Type Paper Type: Not Applicable (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 70° V-twin, two-stroke Displacement: 249 cc (250cc class) Bore X Stroke: 51.0 mm x 60.5 mm Valvetrain: Reed valve induction, rotary disc valves Power Output: Approx. 70-75 HP (depending on model year and market restrictions) Torque: Approx. 35-40 Nm Performance Top Speed: Approx. 140+ mph (225+ km/h) Fuel System Carburetors: 2 x Mikuni TMI 32 (or similar high-performance flat-slide carburetors) Fuel Type: Unleaded gasoline, high octane recommended Oil Injection: Automatic oil injection system for two-stroke lubrication 🔧 Transmission Standard Transmission Type: 6-speed constant mesh sequential gearbox Clutch Type: Wet multi-plate clutch, hydraulically operated Features Gear Ratios: Specific ratios detailed within the manual, optimized for performance. 📐 Dimensions Exterior Length: Approx. 1990 mm Width: Approx. 700 mm Height: Approx. 1120 mm Wheelbase: Approx. 1370 mm Weights Dry Weight: Approx. 140 kg Wet Weight: Approx. 155 kg (with fluids) 🛡️ Safety Features Ratings Safety Ratings: Motorcycles are not typically assigned automotive crash test ratings; safety is derived from design and rider skill. Active Features Braking System: Dual front disc brakes with multi-piston calipers, single rear disc brake. Suspension: Upside-down (USD) front forks and adjustable rear monoshock for stability and control. Passive Features Frame Construction: Aluminum alloy twin-spar frame for rigidity and light weight. 💡 Technology Features Infotainment Infotainment System: Not applicable for this model; focuses on pure performance. Driver Assistance Driver Assistance Systems: None. ABS was not a standard feature on this model. Connectivity Connectivity Features: Not applicable. 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 3,000-5,000 km, or as specified in the manual. Transmission oil every 6,000-10,000 km. Chain Lubrication Adjustment: Regularly, depending on riding conditions. Check manual for specific adjustment procedure. Air Filter Cleaning Replacement: Check/clean every 3,000-5,000 km, replace as needed. Spark Plug Replacement: Typically every 6,000-8,000 km, with specific types recommended. Fluid Specifications Engine Oil Type: Specific high-quality two-stroke premix or injection oil, meeting API TC, JASO FD standards (refer to manual for exact specifications). Transmission Oil Type: API GL-4 or GL-5 gear oil, SAE 75W/90 or similar (refer to manual for exact specifications). Coolant Type: Ethylene glycol-based coolant, typically a 50/50 mix with distilled water (refer to manual for exact specifications). Brake Fluid Type: DOT 4 or DOT 5.1 (refer to manual for exact specifications, often DOT 4 is specified for this era). Known Issues Cylinder...