🏷️ Basic Information Identification Make: Aprilia Model: RS250 Year: 2003 Generation Generation Identifier: MK II Codes Vin Country Code: ZP0 👋 Introduction Market Position Motorcycle Segment: High-performance, two-stroke sportbike Target Audience: Enthusiasts, DIY mechanics, service professionals Competitive Analysis Key Competitors: Yamaha YZF-R6, Suzuki GSX-R600, Kawasaki Ninja ZX-6R, Honda CBR600RR (in their respective class). Key Features Engine Layout: V-twin, liquid-cooled, two-stroke Design Inspiration: Derived from Suzuki RGV250 platform 📋 Manual Details Coverage Areas All Models Engines Trim Transmissions: True Page Count Estimated Page Count: 300-400 Manual Type Manual Type: Workshop Repair Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Complete overhaul, tuning, component testing, lubrication systems, cooling systems Engine Electrical: Ignition system, starting system, charging system, ECU diagnostics, wiring diagrams Fuel System: Carburetor overhaul and tuning (Dell'Orto PHBH 28), fuel pump, fuel lines, tank maintenance Transmission: Gearbox inspection, clutch service, shifting mechanism, gearbox oil specifications Suspension: Front fork (Marzocchi M1R) overhaul, rear shock absorber (Ohlins or Sachs) service, linkage maintenance Brakes: Front and rear brake caliper service, master cylinder overhaul, brake fluid replacement, bleeding procedures, disc inspection Electrical System: Lighting, horn, instrumentation, battery maintenance, fuse box layout, troubleshooting electrical faults Cooling System: Radiator service, fan operation, coolant replacement, thermostat testing Chassis And Bodywork: Frame inspection, fairing removal and installation, seat, handlebars, footpegs Procedures Included Routine Maintenance: Oil changes, filter replacements, chain adjustment, spark plug replacement, air filter cleaning Troubleshooting: Diagnostic flowcharts for common problems, identifying causes of poor performance, starting issues, electrical faults Engine Rebuild: Top-end rebuild (piston, rings, cylinder), bottom-end inspection, crankcase assembly, torque specifications Carburetor Tuning: Jetting recommendations, idle speed adjustment, mixture screw settings, synchronisation (if applicable) Suspension Adjustment: Fork pre-load, rebound, compression adjustments; shock absorber adjustments Brake System Maintenance: Pad replacement, caliper servicing, fluid bleeding techniques, master cylinder seal replacement Electrical Diagnostics: Wiring diagram interpretation, component testing using multimeters, fault finding for ignition and charging systems Wheel And Tire: Tire pressure checks, wheel balancing, rim inspection Technical Depth Depth: Comprehensive: Covers routine maintenance, diagnostics, component overhaul, and full engine/transmission rebuilds. 📊 Manual Specifications File Format File Type: Searchable PDF Resolution: High-resolution, clear text and diagrams Print Quality Printability: Printable pages 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: 90-degree V-twin, liquid-cooled, two-stroke, Reed Valve Displacement: 249 cc Bore X Stroke: 54 x 54.5 mm Compression Ratio: 7.3:1 Power Output Hp: 70 hp (approx. at crank) Torque Nm: 33 Nm (approx. at crank) Lubrication: Autolube (Premix capability with manual intervention) Fuel System Carburetor Model: 2 x Dell'Orto PHBH 28 Fuel Type: Unleaded gasoline (min. 95 RON), 2-stroke oil for autolube system 🔧 Transmission Standard Transmission Type: 6-speed constant mesh Clutch Type: Wet multi-plate Features Gear Ratios: Specific ratios available in manual (e.g., 1st: 2.615, 2nd: 1.941, 3rd: 1.555, 4th: 1.333, 5th: 1.190, 6th: 1.045) Final Drive: Chain drive, 520 pitch 📐 Dimensions Exterior Length: Approx. 1990 mm Width: Approx. 700 mm Height: Approx. 1135 mm Weights Dry Weight: Approx. 140 kg Fuel Tank Capacity: 16 Liters Wheelbase: Approx. 1370 mm 🛡️ Safety Features Ratings Safety Ratings: N/A (Motorcycle safety ratings vary by region and are not directly applicable as vehicle crash test ratings). Active Features Braking System: Dual front 320mm discs with 4-piston calipers, single rear 220mm disc with 2-piston caliper Suspension Design: Performance-oriented front and rear suspension for stability and handling Passive Features Chassis Construction: Aluminum twin-spar frame for rigidity 💡 Technology Features Infotainment Infotainment System: N/A (Focus is on performance and mechanicals, not modern infotainment). 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,000-4,000 km or annually (refer to manual for specific recommendation) Spark Plug Replacement: Every 6,000-8,000 km or as needed based on inspection Chain Lubrication Adjustment: Every 500 km or after riding in wet conditions Air Filter Cleaning: Every 4,000-6,000 km or more frequently in dusty conditions Fluid Specifications Engine Oil Type: High-quality 2-stroke premix oil for autolube system (e.g., Motul 800 2T Factory Line, Castrol TTS) or high-performance synthetic 2-stroke oil. Gearbox Oil Type: API GL-4, SAE 80W/90 gear oil (e.g., Motul Gear 300 75W-90) Coolant Type: Ethylene glycol-based coolant with anti-corrosion additives, typically a 50/50 mix with distilled water. Brake Fluid Type: DOT 4 brake fluid Known Issues Common Problems: Carbon buildup in exhaust and power valves, reed valve wear, carburetor jetting sensitivity, potential for crankshaft seal leaks, clutch wear. Maintenance Tips: Regular cleaning of power valves is crucial for performance; proper jetting for altitude and temperature is essential; use high-quality 2-stroke oil. 📚 Vehicle History Brand Heritage Aprilia Legacy: Aprilia has a strong heritage in Grand Prix racing, particularly with its successful 250cc two-stroke machines. Model Evolution Rs250 Lineage: The RS250 is a direct evolution of the Suzuki RGV250 Gamma, with Aprilia incorporating its own chassis design and...