🏷️ Basic Information Identification Make: Aprilia Model: RS250 Model Years Covered: 1994, 1995, 1996, 1997, 1998 Codes Product Name Identifier: Aprilia RS250 1994-1998 Factory Service Manual Repair PDF 👋 Introduction Market Position Positioning Statement: The Aprilia RS250 was a highly regarded, track-focused sportbike known for its exceptional handling and potent two-stroke performance, designed to compete with larger capacity machines. Competitive Analysis Key Competitors: Suzuki RGV250, Yamaha TZR250, Kawasaki KR-1S. Key Features Handling Prowess: Renowned for its aluminium twin-spar frame derived from the RSW GP racing bikes and sophisticated suspension, offering exceptional agility and feedback. Engine Performance: Powered by a V-twin, liquid-cooled two-stroke engine, delivering exhilarating power delivery and a distinctive exhaust note. 📋 Manual Details Coverage Areas Manual Type: Factory Service Manual / Repair Manual Language: English Format: PDF (Digital Download) Page Count Estimated Page Count: Approximately 300+ pages (typical for this era and scope) 📖 Manual Coverage Systems Covered Engine: Complete overhaul, top-end and bottom-end disassembly/assembly, lubrication, cooling system, fuel system (carburetors, fuel lines), exhaust system. Transmission: Gearbox disassembly/assembly, clutch operation and servicing, gear shift mechanism, lubrication. Chassis And Suspension: Front fork (D.O.C. Phase I/II/III depending on year/spec) service and adjustment, rear shock absorber servicing and adjustment, swingarm maintenance, steering head bearing service, wheel bearing service. Brakes: Front and rear brake system diagnosis and repair, caliper servicing, master cylinder overhaul, brake fluid replacement and bleeding, rotor inspection. Electrical System: Wiring diagrams, ignition system diagnosis and components (CDI, coils, spark plugs), lighting system, instrumentation, battery maintenance, starter motor, charging system (alternator/stator). Bodywork And Fairings: Fairing removal and installation, seat servicing, fuel tank maintenance, general body panel repairs and alignment. Procedures Included Maintenance: Scheduled maintenance tasks, lubrication points and intervals, fluid level checks, filter replacements, chain adjustment, brake pad inspection. Troubleshooting: Diagnostic flowcharts for common performance issues, electrical faults, starting problems, and handling anomalies. Repair: Detailed step-by-step instructions for component replacement, adjustments, and complete overhauls of major systems. Technical Specifications: Torque specifications for all fasteners, engine timings, carburetion settings, suspension sag measurements, electrical component resistance values. Technical Depth Depth Of Coverage: Comprehensive from basic rider maintenance to complete engine and chassis rebuilds, including diagnostic procedures for advanced issues. Suitable for professional technicians and experienced home mechanics. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable if original scan quality is good, allowing quick navigation to specific topics. Print Quality Digital Quality: Dependent on original scan; generally expected to be clear enough for legibility of text and diagrams. Binding Type Digital Format: N/A (Digital Download) Paper Type Digital Format: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: V-twin, two-stroke, liquid-cooled, reed valve induction Displacement: 249 cc (249.3 cc) Bore X Stroke: 54 mm x 54.5 mm Compression Ratio: 7.2:1 (approx.) Performance Horsepower: Approx. 65-70 HP (at crankshaft, depending on market and specific model year tuning) Torque: Approx. 36-38 Nm (at crankshaft, depending on market and specific model year tuning) Fuel System Carburetors: 2x Mikuni TM34SS flat-slide carburetors Fuel Type: Unleaded gasoline (minimum 95 RON recommended), requires 2-stroke oil pre-mix or automatic injection system. Lubrication Oil System: Automatic oil injection system with separate oil reservoir. Cooling System Type: Liquid-cooled 🔧 Transmission Standard Transmission Type: 6-speed constant mesh Gear Ratios: Specific ratios will be detailed in the manual, typically optimized for performance. Features Clutch Type: Wet multi-plate clutch 📐 Dimensions Exterior Length: Approx. 1980 mm (78 in) Width: Approx. 700 mm (27.5 in) Height: Approx. 1120 mm (44 in) Wheelbase: Approx. 1370 mm (53.9 in) Weights Dry Weight: Approx. 141 kg (311 lbs) Fuel Capacity: Approx. 17 liters (4.5 US gal) 🛡️ Safety Features Ratings Crash Test Ratings: N/A (Motorcycle specific safety is evaluated through component performance and handling rather than car-style crash tests). Active Features Braking System: Dual front disc brakes (e.g., 320mm diameter, 4-piston calipers), Single rear disc brake (e.g., 240mm diameter, 2-piston caliper). Specific caliper brands like Brembo may be featured. ABS was not typically available on these models. Suspension System: Adjustable front forks (e.g., upside-down telescopic, Showa or Marzocchi) and adjustable rear monoshock suspension for precise control. Passive Features Frame Construction: Lightweight aluminium alloy twin-spar frame for rigidity and precise handling. Lighting: Halogen headlight, taillight, and turn signals. 💡 Technology Features Infotainment Dashboard Instrumentation: Analog tachometer, speedometer, coolant temperature gauge, and indicator lights. Minimal electronic integration typical for the era. Driver Assistance ABS: Not typically equipped with ABS. Connectivity Electronic Systems: Features an electronic power valve system and CDI ignition, which require specific diagnostic and service procedures detailed in the manual. 🔧 Maintenance Service Intervals Oil Change Interval: Refer to manual for specific mileage intervals for gearbox oil and 2-stroke oil. Engine oil (gearbox oil) typically every 5,000-10,000 km. Spark Plug Replacement: Recommended replacement at intervals specified in the manual, often around 5,000-8,000 km, depending on riding style and plug type (e.g., NGK BR9EG). Chain And...