🏷️ Basic Information Identification Make: Aprilia Model: RS250 Year: 2002 Product Name: Aprilia RS250 2002 Service Repair Workshop Manual Codes Vin Prefix: ZA01 👋 Introduction Market Position Segment: Lightweight two-stroke supersport motorcycle Competitors: Yamaha YZF-R6, Suzuki GSX-R600, Honda CBR600F/RR (though the RS250 occupied a unique niche due to its two-stroke engine) Target Audience: Enthusiast riders, track day participants, experienced mechanics Key Features Engine Type: Liquid-cooled, 249cc, V-twin two-stroke engine Performance Focus: High power-to-weight ratio, sharp handling, exhilarating two-stroke power delivery Design Inspiration: Derived from Aprilia's Grand Prix racing technology 📋 Manual Details Coverage Areas Manual Type: Service Repair Workshop Manual Language: English Format: Digital (likely PDF, though not explicitly stated, typical for workshop manuals sold this way) Coverage Scope: Comprehensive full service and repair instructions used by mechanics worldwide Page Count Estimated Page Count: Likely 300-500 pages (typical for detailed service manuals of this era and complexity) 📖 Manual Coverage Systems Covered Engine Systems: Engine overhaul, top-end rebuild, bottom-end assembly, cooling system, lubrication system, fuel delivery (carburetors), ignition system, exhaust system Transmission Drivetrain: Gearbox internals, clutch operation and service, chain and sprocket maintenance, final drive Chassis Suspension: Front fork (telescopic, upside-down) service and tuning, rear shock absorber (monoshock) service, swingarm and linkage maintenance, steering head bearing service Braking System: Front and rear brake caliper service, master cylinder overhaul, brake line replacement, bleeding procedures, pad and disc inspection/replacement Electrical System: Wiring diagrams, lighting system, charging system (alternator, regulator/rectifier), ignition coil troubleshooting, starter motor service, battery maintenance, instrument cluster diagnostics Fuel System: Carburetor identification (likely Mikuni T25-1), tuning and synchronization, fuel tank removal and installation, fuel petcock service Cooling System: Radiator service, coolant replacement, thermostat operation, water pump inspection Procedures Included Routine Maintenance: Oil changes, filter replacements, chain lubrication and adjustment, spark plug inspection/replacement, air filter cleaning/replacement, general inspection checklist Diagnostic Troubleshooting: Step-by-step guides for identifying and resolving common mechanical and electrical issues, fault codes (if applicable for the era), performance tuning advice Rebuild Procedures: Complete engine teardown and reassembly, gearbox overhauls, carburetor rebuilds, suspension component rebuilding Assembly Disassembly: Detailed instructions for removing and reinstalling all major components and sub-assemblies Torque Specifications: Crucial torque values for critical fasteners throughout the motorcycle Technical Depth Diagnostic Capabilities: Advanced diagnostics for engine performance, ignition timing, fuel mixture, and electrical faults Rebuild Level: Full engine rebuild, gearbox rebuild, suspension fork rebuild, carburetor overhaul Tuning Guidance: Carburetor jetting, ignition timing adjustments, suspension setup recommendations 📊 Manual Specifications File Format Digital Format: PDF (standard for digital workshop manuals) Searchability: Likely searchable text, facilitating quick access to information Print Quality: High resolution for clear diagrams and text when printed Binding Type Physical Manual Binding: N/A (assuming digital format, but if printed, would be spiral-bound or perfect bound) Paper Type Physical Manual Paper: N/A (assuming digital format, but if printed, would be high-quality, durable paper) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 90-degree V-twin, two-stroke Displacement: 249.2 cc (15.2 cubic inches) Bore X Stroke: 54.0 mm x 54.5 mm Compression Ratio: 12.5:1 (typical, may vary slightly) Valve Train: Reed valve induction, Aprilia Variable Intake System (AVIS) Performance Horsepower: Approx. 70 HP @ 11,750 rpm (claimed, actual may vary) Torque: Approx. 39 Nm (28.7 lb-ft) @ 10,500 rpm (claimed, actual may vary) Fuel System Carburetors: 2 x Mikuni T25-1 flat-slide carburetors Fuel Type: Unleaded gasoline, minimum 95 RON (octane rating), requires two-stroke oil pre-mix or oil injection system Lubrication Oil System: Separate oil injection system (or pre-mix capability) Ignition Ignition System: Digital CDI (Capacitor Discharge Ignition) 🔧 Transmission Standard Transmission Type: 6-speed, constant mesh Clutch Type: Wet multi-plate, cable-actuated Features Gear Ratios: Specific ratios will be detailed in the manual; typically close-ratio for performance Final Drive: Chain drive, 520 pitch (typical) 📐 Dimensions Exterior Length: Approx. 1,960 mm (77.2 in) Width: Approx. 720 mm (28.3 in) at handlebars Height: Approx. 1,100 mm (43.3 in) at seat Wheelbase: Approx. 1,370 mm (53.9 in) Weights Dry Weight: Approx. 140 kg (308.6 lbs) Wet Weight: Approx. 165 kg (363.8 lbs) (fully fueled, typical) Fuel Tank Capacity: 16 liters (4.2 US gallons) 🛡️ Safety Features Ratings Safety Certification: CE, DOT, ECE (depending on market of sale; this manual covers general service) Active Features Braking System Type: Dual front disc brakes, single rear disc brake Brake Rotor Diameter Front: 290 mm (typical) Brake Rotor Diameter Rear: 220 mm (typical) Passive Features Frame Type: Aluminum twin-spar frame Suspension Type Front: Upside-down telescopic fork, adjustable preload and damping Suspension Type Rear: Monoshock with linkage, adjustable preload and damping 💡 Technology Features Infotainment Infotainment System: N/A (Basic analogue instrumentation) Driver Assistance Rider Aids: None (No electronic rider aids such as ABS, traction control, or ride modes were available) 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,000-5,000 km (1,800-3,000 miles) or annually; consult manual for specific recommendations based on usage. Chain Maintenance: Lubricate and adjust every 500-1000 km...