🏷️ Basic Information Identification Make: Aprilia Model: RS 250 Model Years Covered: 1995, 1996, 1997 Codes Chassis Code: AP04 Engine Code: Rotax 2-stroke V-twin 👋 Introduction Market Position Market Segment: High-performance sportbike, often considered a homologation special for racing. Target Audience: Enthusiasts, track day riders, and owners requiring in-depth maintenance and repair knowledge. Competitive Analysis Key Competitors: Yamaha YZF-R6, Suzuki GSX-R600, Honda CBR600F series, Kawasaki Ninja ZX-6R. Aprilia Advantage: Unique V-twin 2-stroke engine, exceptional handling derived from racing pedigree, distinctive styling. Key Features Engine Configuration: 2-stroke, V-twin, liquid-cooled Suspension Components: High-quality Marzocchi front forks and often Ohlins rear shock (depending on market/trim). Braking Components: Powerful twin-disc front brakes with Brembo calipers. Design Philosophy: Race-inspired design, lightweight chassis, aerodynamic fairings. 📋 Manual Details Coverage Areas Systems Covered: Engine, Fuel System, Ignition System, Exhaust System, Transmission, Clutch, Chassis, Suspension (Front & Rear), Braking System (Front & Rear), Electrical System, Cooling System, Lubrication System, Bodywork, Wheels & Tires, Troubleshooting, Maintenance Schedules, Specifications Page Count Page Count: Approximately 250-300 pages (estimated for a comprehensive service manual of this era) Manual Type Manual Type: Factory Service Manual / Workshop Manual Language Language: English Format Format: PDF (Digital Download) 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed breakdown of cylinder head, cylinders, pistons, crankshaft, connecting rods, lubrication system, and cooling system. Includes torque specifications, clearances, and assembly procedures. Fuel System: Carburetor tuning, jetting, float bowl adjustment, fuel pump operation, fuel tank maintenance, and fuel line inspection. Ignition System: CDI ignition, spark plug specifications, timing adjustments, and troubleshooting ignition failures. Transmission Clutch: Gearbox disassembly and reassembly, clutch plate inspection, adjustment, and replacement procedures. Includes gear ratios and lubrication requirements. Suspension Steering: Front fork (Marzocchi) disassembly, reassembly, oil type, level, and damping adjustments. Rear shock absorber (Ohlins on some variants) service and adjustment. Steering head bearing maintenance and replacement. Braking System: Front and rear brake caliper service, master cylinder overhaul, brake pad replacement, fluid flush and bleeding procedures. Includes specifications for brake fluid type (DOT 4) and recommended service intervals. Electrical System: Wiring diagrams, component testing (stator, regulator/rectifier, battery), lighting systems, starter motor, and battery charging system diagnosis. Chassis Frame: Frame inspection, alignment checks, and component mounting points. Bodywork Trim: Fairing removal and installation, seat, fuel tank, and paneling components. Procedures Included Routine Maintenance: Oil changes, filter replacements, chain adjustment and lubrication, tire pressure checks, brake system inspection, and bolt torque checks. Troubleshooting: Systematic diagnostic guides for common issues such as starting problems, poor running, ignition faults, and braking system issues. Major Repairs: Engine rebuilds, transmission overhauls, suspension component replacement, and electrical system component diagnosis and repair. Component Replacement: Detailed steps for replacing parts like brake pads, spark plugs, air filters, oil filters, clutch plates, and various seals. Technical Depth Diagnostic Capabilities: Comprehensive diagnostic procedures for all major systems, enabling identification and resolution of a wide range of performance issues. Rebuild Procedures: Complete step-by-step instructions for engine, transmission, and suspension rebuilds, including detailed diagrams and torque specifications. Specifications Data: Inclusion of all critical technical data such as clearances, tolerances, fluid capacities, torque values, electrical resistance, and tuning parameters. 📊 Manual Specifications File Format File Format: PDF Searchability: Searchable text for quick information retrieval Print Quality Print Quality: High-resolution, clear diagrams and text suitable for printing Binding Type Binding Type: N/A (Digital) Paper Type Paper Type: N/A (Digital) ⚙️ Engine Specifications Primary Engine Engine Type: 2-stroke, liquid-cooled, 80-degree V-twin Displacement: 249 cc Bore X Stroke: 54 mm x 54.5 mm Compression Ratio: 7.0:1 (approx.) Induction: Dual 32mm Mikuni flat-slide carburetors (VM32SS) Ignition: Digital CDI with dual spark plugs per cylinder Lubrication: Premix or automatic oil injection system (depending on market/specific model year) Performance Horsepower: Approximately 70-74 hp @ 11,000 rpm (claimed) Torque: Approximately 40-42 Nm (29-31 lb-ft) @ 10,000 rpm (claimed) Fuel System Fuel Type: Unleaded gasoline (min. 95 RON) Oil Type: High-quality 2-stroke synthetic oil (specified in manual) 🔧 Transmission Standard Transmission Type: 6-speed sequential manual Clutch Type: Wet multi-plate clutch Features Gear Ratios: Specific ratios detailed in the manual (e.g., 1st: 2.46, 2nd: 1.77, 3rd: 1.40, 4th: 1.15, 5th: 0.96, 6th: 0.84 - typical values, consult manual for exact ratios) Final Drive: Chain drive Transmission Oil: Manual specifies specific gear oil (e.g., SAE 75W-90 or similar GL-4 rated gear oil) 📐 Dimensions Exterior Length: Approx. 2,000 mm (78.7 in) Width: Approx. 710 mm (28.0 in) Height: Approx. 1,120 mm (44.1 in) Wheelbase: Approx. 1,370 mm (53.9 in) Weights Dry Weight: Approx. 138 kg (304 lbs) Fuel Tank Capacity: 16 liters (4.2 US gal) Oil Tank Capacity: 1.5 liters (0.4 US gal) 🛡️ Safety Features Ratings Safety Ratings: N/A (Motorcycles are not typically rated by organizations like NHTSA or Euro NCAP in the same way cars are. Safety is primarily inherent in design and rider skill.) Active Features Braking System: Dual 320mm front discs with 4-piston calipers, single...