🏷️ Basic Information Identification Make: Aprilia Model: RS250 Codes Product Identifier: Workshop Service Manual Repair 👋 Introduction Market Position Segment: Lightweight, high-performance supersport motorcycle, competing in the 250cc racing replica class. Target Audience: Enthusiasts, track day riders, and owners seeking to maintain or restore their Aprilia RS250. Competitive Analysis Competitors: Yamaha YZF-R250, Honda CBR250RR (MC28), Suzuki RGV250, Kawasaki KR-1S. Key Features Engine Type: Liquid-cooled, 90-degree V-twin, 2-stroke, reed valve induction. Performance Focus: Lightweight chassis, potent 2-stroke power delivery, excellent handling characteristics. Design Inspiration: Derived from Aprilia's Grand Prix racing technology, particularly the RS250 GP machine. 📋 Manual Details Coverage Areas Applicable Years: 1994, 1995, 1996, 1997, 1998 Page Count Estimated Pages: Refer to actual document for exact page count, but workshop manuals of this era typically range from 250-500 pages. Manual Type Type: Workshop Service Manual / Repair Manual Language Language: English (standard for most Aprilia service documentation of this period, verify with actual product) Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Comprehensive coverage of the 249cc V-twin 2-stroke engine, including disassembly, assembly, tuning, and troubleshooting. Fuel System: Carburetor tuning (Mikuni TMR 34mm likely), fuel pump, fuel lines, and tank servicing. Ignition System: CDI unit, ignition timing, spark plugs, and related wiring. Cooling System: Radiator, cooling fan, coolant flow, and associated hoses and components. Exhaust System: Expansion chambers, silencers, and associated fittings. Transmission: 6-speed gearbox, clutch operation, lubrication, and internal component servicing. Chassis Frame: Aluminum twin-spar frame inspection, alignment checks, and component mounting. Suspension Front: 38mm upside-down (USD) forks (likely Showa or Marzocchi), damping adjustment, oil levels, seal replacement, and fork leg servicing. Suspension Rear: Monoshock rear suspension, linkage system, shock absorber adjustment and servicing, swingarm removal and maintenance. Brakes Front: Dual disc setup, caliper servicing, pad replacement, master cylinder overhaul, bleeding procedures, and rotor specifications. Brakes Rear: Single disc setup, caliper servicing, pad replacement, master cylinder overhaul, bleeding procedures, and rotor specifications. Wheels Tires: Wheel bearing servicing, rim maintenance, tire mounting and balancing, and recommended tire pressures. Electrical System: Wiring diagrams, lighting, battery maintenance, charging system (stator, regulator/rectifier), starter motor, and switches. Bodywork Fairings: Fairing removal and installation, panel fitting, seat servicing, and accessory mounting. Controls: Throttle, clutch, and brake lever adjustments, cable routing, and control housing maintenance. Procedures Included Routine Maintenance: Oil changes, chain adjustment and lubrication, filter replacement, spark plug checks, and general inspection procedures. Engine Overhaul: Complete engine disassembly, inspection of pistons, rings, cylinders, crankshaft, and reassembly procedures. Suspension Rebuild: Detailed steps for fork seal replacement, fork oil changes, and rear shock servicing. Brake System Service: Bleeding procedures, pad replacement, caliper servicing, and master cylinder rebuilding. Electrical Troubleshooting: Diagnosis of common electrical faults using wiring diagrams and test procedures. Carburetor Tuning: Jetting recommendations, idle speed adjustment, mixture control, and sync procedures. Clutch Adjustment: Cable adjustment and clutch plate inspection/replacement. Transmission Service: Gearbox oil changes and potential internal component inspection. Bodywork Repair: Instructions for removing and refitting body panels, and potential minor repair guidance. Technical Depth Depth: Comprehensive, covering everything from basic maintenance checks to complete engine and chassis overhauls. Includes detailed diagnostic procedures and specifications. Diagnostic Capabilities: Detailed fault finding guides for engine performance, electrical issues, and chassis components. Rebuild Instructions: Step-by-step instructions with diagrams for major component rebuilds. 📊 Manual Specifications File Format Format: PDF Searchable: Likely searchable if properly OCR'd, enhancing usability for quick information retrieval. Print Quality Printability: Designed for digital viewing but typically printable for workshop use. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 90-degree V-twin, 2-stroke Displacement: 249 cc Bore X Stroke: 54.0 mm x 54.5 mm Power Output: Approximately 70-72 hp at 11,000 rpm (claimed, varies by market and tuning). Torque: Approximately 41 Nm (29.5 lb-ft) at 10,000 rpm (claimed). Compression Ratio: Typically around 7.0:1 (variable with porting). Induction: Reed valve, twin Mikuni TMR 34mm carburetors (common for later models/upgrades). Ignition: Digital CDI Lubrication: Premix or separate oil injection system (check specific model variant). Fuel System Carburetors: Mikuni TMR 34mm (common, earlier models might have VM28SS). Fuel Type: Unleaded gasoline, minimum 95 RON (premium). Performance Top Speed: Exceeds 220 km/h (137 mph). 0-100 Kmh: Approximately 4.5 seconds. 🔧 Transmission Standard Gearbox: 6-speed constant mesh Clutch: Wet multi-plate, cable operated Features Final Drive: Chain drive Gear Ratios: Specific ratios detailed in the manual, crucial for performance tuning. Transmission Oil Type: SAE 10W-30 or 20W-40 motorcycle gear oil (refer to manual for precise Aprilia specification). 📐 Dimensions Exterior Length: Approx. 1990 mm (78.3 in) Width: Approx. 720 mm (28.3 in) Height: Approx. 1115 mm (43.9 in) Wheelbase: Approx. 1365 mm (53.7 in) Weights Dry Weight: Approx. 140 kg (309 lbs) Wet Weight: Approx. 150 kg (331 lbs) (estimated, including fluids) Fuel Capacity: 16 liters (4.2 US gal) 🛡️ Safety Features Active Features Brakes: High-performance...