🏷️ Basic Information Identification Make: Aprilia Model: RS250 Year: 1996 Manual Product Name: Aprilia RS250 1996 All Service Repair Manual Download 👋 Introduction Market Position Segment: High-performance lightweight sportbike Target Audience: Enthusiasts and owners seeking to maintain and repair their Aprilia RS250 Competitive Analysis Competitors: Suzuki RGV250, Yamaha TZR250, Kawasaki KR-1S Key Features Engine Design: Two-stroke V-twin engine derived from Suzuki RGV250 components Handling: Renowned for sharp handling and race-inspired chassis dynamics Performance: Strong power-to-weight ratio and exhilarating acceleration 📋 Manual Details Coverage Areas Primary Coverage: Comprehensive service and repair information Scope: All systems and components of the Aprilia RS250 (1996) Page Count Estimated Pages: Approximately 300-400 pages (typical for this era's service manuals) Manual Type Type: Service Repair Manual Language Language: English Format Format: Downloadable Digital Format (likely PDF) 📖 Manual Coverage Systems Covered Engine: Complete engine assembly, disassembly, tuning, and diagnostics Fuel System: Carburetor service (Mikuni TM28SS), fuel pump, fuel lines, fuel tank Ignition System: CDI, ignition coils, spark plugs, timing adjustments Cooling System: Radiator, water pump, coolant flow, thermostat Exhaust System: Expansion chambers, mufflers, gaskets Transmission: Gearbox assembly, clutch operation (wet multi-plate), gear shifting mechanism Drivetrain: Chain and sprockets maintenance and replacement Brakes: Front and rear brake systems (calipers, master cylinders, lines, pads, rotors) Suspension: Front telescopic forks (adjustable), rear monoshock (adjustable), linkage Steering: Steering head bearings, handlebar assembly Electrical System: Wiring diagrams, lighting, battery, charging system, starter motor Chassis Frame: Frame inspection, alignment checks Bodywork: Fairing removal and installation, seat, fuel tank paneling Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, chain lubrication Troubleshooting: Diagnostic procedures for common issues and system malfunctions Repair: Detailed step-by-step instructions for component repair and replacement Rebuilds: Engine, transmission, and suspension component rebuild procedures Adjustments: Carburetor synchronization, ignition timing, suspension sag, clutch play Specifications Torque: Torque specifications for all critical fasteners Technical Depth Depth: In-depth technical coverage suitable for professional mechanics and experienced DIY enthusiasts Diagnostics: Advanced diagnostic information, including fault codes (if applicable) and systematic troubleshooting guides Rebuild Manuals: Includes procedures for complete engine and gearbox rebuilds 📊 Manual Specifications File Format Digital Format: PDF (Portable Document Format) Searchable: Likely searchable text for quick information retrieval Printable: Printable pages for workshop use Print Quality Quality: High-resolution scans with clear diagrams and text Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Type: Liquid-cooled, 2-stroke, V-twin Displacement: 249 cc (249.02 cc) Bore X Stroke: 54 mm x 54.5 mm Compression Ratio: 7.5:1 Valves Per Cylinder: Reed valve induction Performance Horsepower: Approx. 70-75 HP (at crankshaft, depending on market regulations and tuning) Torque: Approx. 38 Nm (28 lb-ft) @ 8,000 rpm Fuel System Carburetors: 2 x Mikuni TM28SS flat-slide carburetors Fuel Delivery: Fuel pump with auto-lube (mixture oil injection system) Ignition System Ignition Type: Digital CDI 🔧 Transmission Standard Type: 6-speed constant mesh Features Clutch: Wet multi-plate clutch Final Drive: O-ring sealed chain 📐 Dimensions Exterior Length: Approx. 1985 mm (78.1 in) Width: Approx. 710 mm (28.0 in) Height: Approx. 1135 mm (44.7 in) Wheelbase: Approx. 1390 mm (54.7 in) Weights Dry Weight: Approx. 143 kg (315 lbs) Wet Weight: Approx. 155 kg (342 lbs) 🛡️ Safety Features Ratings Certification: N/A (Motorcycle safety ratings differ from cars) Active Features Brakes: Dual front discs (320mm), single rear disc (230mm) with twin-piston calipers ( Nissin) Tires: Sport-oriented tire compounds Passive Features Frame: Aluminum twin-spar frame for rigidity and rider feedback Lighting: Halogen headlight, LED taillight 💡 Technology Features Infotainment Dashboard: Analog speedometer, tachometer, coolant temperature gauge, and essential warning lights. Driver Assistance Features: N/A (Focus on rider engagement and mechanical feedback) 🔧 Maintenance Service Intervals Oil Change: Every 3,000-5,000 km (1,800-3,100 miles) or annually Spark Plugs: Inspect every 5,000 km (3,100 miles), replace as needed (NGK BR9EG recommended) Air Filter: Clean or replace every 5,000 km (3,100 miles) Chain Lubrication: Every 500-750 km (300-450 miles) and after washing/rain Coolant Flush: Every 2 years or 20,000 km (12,500 miles) Fluid Specifications Engine Oil Type: 2-stroke pre-mix oil (specific recommendations vary, e.g., Motul 800 2T Factory Line) or Auto-lube injection oil Coolant: Ethylene glycol-based coolant (50/50 mix with distilled water) Brake Fluid: DOT 4 Clutch Fluid: DOT 4 Known Issues Common Problems: Potential for power valve issues, reed valve wear, and clutch wear due to aggressive riding. Carburetor synchronization critical for smooth running. Maintenance Tip: Regular cleaning and adjustment of the Mikuni carburetors are crucial for optimal performance. 📚 Vehicle History Brand Heritage Heritage: Aprilia is an Italian manufacturer with a strong racing pedigree, particularly in Grand Prix motorcycle racing. Model Evolution Origin: The RS250 was developed in collaboration with Suzuki, utilizing the engine and many chassis components from the highly successful Suzuki RGV250 Gamma. Key Years: Introduced in 1995, the 1996 model is part of the early production run. Later models received updates. Production Manufacturing Location:...