🏷️ Basic Information Identification Make: Aprilia Model: RS250 Model Years Covered: 1998, 1999, 2000, 2001, 2002, 2003, 2004 Product Name: Aprilia RS250 1998-2004 Service Repair Workshop Manual 👋 Introduction Market Position Market Position: The Aprilia RS250 was a performance-oriented supersport motorcycle, a cult classic known for its potent 2-stroke V-twin engine and exceptional handling, competing with bikes like the Yamaha R6 and Suzuki GSX-R600 of its era. Competitive Analysis Key Competitors: Yamaha YZF-R6, Suzuki GSX-R600, Kawasaki Ninja ZX-6R, Ducati 750SS. Key Features Unique Selling Points: Two-stroke V-twin engine derived from Suzuki's RGV250, lightweight chassis, advanced suspension and braking for its time, aggressive styling. 📋 Manual Details Coverage Areas Systems Covered: Engine, Fuel System, Ignition System, Cooling System, Lubrication System, Exhaust System, Transmission, Clutch, Chassis, Suspension (Front & Rear), Brakes (Front & Rear), Electrical System, Wiring Diagrams, Bodywork, Frame, Maintenance, Troubleshooting, Diagnostics, Specifications Page Count Page Count: Estimated 300+ pages (typical for comprehensive workshop manuals) Manual Type Manual Type: Service Repair Workshop Manual Language Language: English (standard for this type of manual) Format Format: Likely Digital (PDF), potentially printed 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed disassembly, inspection, repair, and reassembly of the 2-stroke V-twin engine, including cylinder head, cylinder, piston, crankshaft, connecting rods, engine cases, and timing components. Fuel System: Carburetor adjustment and overhaul (likely Mikuni TM34), fuel pump operation, fuel lines, and fuel tank maintenance. Ignition System: CDI ignition system troubleshooting, spark plug specifications, coil testing, and stator/rotor inspection. Cooling System: Radiator, coolant hoses, water pump maintenance, bleeding procedures, and thermostat operation. Lubrication System: Oil injection system maintenance, oil pump operation, and oil type specifications. Exhaust System: Expansion chamber inspection and maintenance, mufflers, and exhaust pipe gaskets. Transmission: Gearbox disassembly, inspection, and reassembly, clutch operation (wet multi-plate), clutch lever adjustment, and transmission oil specifications. Chassis And Frame: Frame inspection, steering head bearing adjustment, swingarm maintenance, and rear shock absorber adjustment. Front Suspension: Fork seal replacement, oil level and type specifications, spring preload adjustment, and damping adjustment (if applicable). Rear Suspension: Monoshock absorber service, linkage maintenance, and adjustment procedures. Front Brakes: Brake caliper overhaul, brake pad replacement, master cylinder service, brake fluid type and bleeding procedures, rotor inspection. Rear Brakes: Brake caliper overhaul, brake pad replacement, master cylinder service, brake fluid type and bleeding procedures, rotor inspection. Electrical System: Battery maintenance, lighting system troubleshooting, horn, starter motor, and wiring harness diagrams. Bodywork: Fairing removal and installation, seat, fuel tank, and accessory fitting. Procedures Included Scheduled Maintenance: Oil changes, filter replacements, chain adjustment, brake inspections, and general lubrication. Troubleshooting: Diagnostic guides for common problems related to engine performance, starting issues, electrical faults, and braking system issues. Engine Rebuild: Complete step-by-step instructions for engine disassembly, part inspection, machining recommendations, and reassembly for full engine overhauls. Suspension Service: Front fork oil changes, seal replacement, and rear shock servicing. Brake System Overhaul: Disassembly, cleaning, and reassembly of brake calipers, master cylinders, and bleeding of the hydraulic system. Electrical Diagnostics: Troubleshooting using wiring diagrams, testing of electrical components, and fault finding. Carburetor Tuning: Detailed instructions for adjusting and synchronizing the Mikuni TM34 carburetors for optimal performance. Technical Depth Depth: Comprehensive, suitable for professional mechanics and advanced DIY enthusiasts. Covers everything from routine maintenance to complete engine and chassis rebuilds. 📊 Manual Specifications File Format File Format: PDF (most likely), potentially a scanned or digitally created document. Print Quality Print Quality: High-resolution scans or professionally digitized content, ensuring clear diagrams and text. Binding Type Binding Type: N/A (for digital format). If printed, typically spiral-bound or perfect-bound for durability. Paper Type Paper Type: N/A (for digital format). If printed, high-quality, durable paper suitable for workshop environments. ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 2-stroke, 90-degree V-twin Displacement: 249cc Bore X Stroke: 54 mm x 54.5 mm Power Delivery: Peak power typically around 70-72 hp at higher RPM, characteristic strong mid-range and top-end power of a 2-stroke. Torque: Approx. 40-42 Nm (29.5-31 lb-ft) at approximately 8,500-9,000 RPM. Compression Ratio: 7.1:1 (for later models, can vary slightly) Fuel System Carburetor: Twin Mikuni TM34SS flat-slide carburetors Fuel Induction: Oil injection system for pre-mix lubrication Ignition System Ignition Type: Digital CDI (Capacitor Discharge Ignition) Cooling System Cooling Type: Liquid-cooled Lubrication System Lubrication Method: Separate oil injection for crankcase and cylinders, with engine oil for transmission/clutch. 🔧 Transmission Standard Transmission Type: 6-speed constant mesh Features Clutch Type: Wet, multi-plate Final Drive: Chain drive 📐 Dimensions Exterior Length: Approx. 1990 mm (78.3 in) Width: Approx. 720 mm (28.3 in) Height: Approx. 1135 mm (44.7 in) Wheelbase: Approx. 1365 mm (53.7 in) Weights Dry Weight: Approx. 140 kg (308.6 lbs) Wet Weight: Approx. 165 kg (363.8 lbs) (with all fluids) Tires Front Tire Size: 120/70ZR17 Rear Tire Size: 160/60ZR17 Wheels Wheel Type: Cast alloy 🛡️ Safety Features Ratings Safety Features Availability: As a performance sportbike of its era, primary safety features are...