The Aprilia RS 250, produced between 1997 and 1998, is a distinguished two-stroke sportbike celebrated for its outstanding handling, aggressive design, and potent V-twin engine derived from Suzuki's RGV250. This model is renowned for its agile chassis, offering superior cornering ability that reflects Aprilia's strong racing heritage. Its performance-oriented nature, coupled with its direct competition against other premium 250cc two-stroke machines of the era, has cemented its status as a highly sought-after motorcycle among enthusiasts and collectors. This comprehensive workshop manual serves as an essential resource for owners and technicians seeking to maintain, diagnose, and repair the Aprilia RS 250 (MK1, AP02A). It covers a wide array of systems, including the fuel, cooling, engine lubrication, clutch, and transmission systems, as well as detailed information on the engine's top end, removal, and installation. Furthermore, the manual provides in-depth guidance on chassis components such as wheels, tires, brakes, suspension, steering, and the frame, alongside complete electrical system coverage with wiring diagrams. The scope includes routine maintenance, detailed troubleshooting procedures, repair and rebuild instructions, and specific technical data, ensuring the longevity and optimal performance of the motorcycle. 🏷️ Basic Information Identification Make: Aprilia Model: RS 250 Year: 1997-1998 Codes Model Codes: Aprilia RS 250 (MK1, AP02A) 👋 Introduction Market Position Market Position: The Aprilia RS 250 was a highly regarded, high-performance two-stroke sportbike known for its exceptional handling and aggressive styling, directly competing with other 250cc two-stroke machines of its era. Competitive Analysis Competitors: Honda NSR250R, Suzuki RGV250, Yamaha TZR250, Kawasaki KR-1S. Key Features Handling: Renowned for its agile chassis and superior cornering ability, a hallmark of Aprilia sportbikes. Engine Technology: Powered by a potent V-twin two-stroke engine, derived from Suzuki's RGV250 platform. Design: Aggressive sportbike styling with aerodynamic fairings and a race-inspired riding position. Manual Value Proposition Value: Provides comprehensive, technician-level information to effectively maintain, diagnose, and repair the Aprilia RS 250, saving time and money on repairs. 📋 Manual Details Coverage Areas Systems Covered: General Information, Fuel System, Cooling System, Engine Top End, Clutch, Engine Lubrication System, Engine Removal/Installation, Crankshaft/Transmission, Wheels/Tires, Final Drive, Brakes, Suspension, Steering, Frame, Electrical System, Appendix Page Count Page Count: Estimated 300-400 pages (typical for a full workshop manual of this era, actual count not provided) Manual Type Manual Type: Workshop Manual / Service Manual / Repair Manual / Factory Service Manual (FSM) Language Language: English Format Format: PDF Download (contained within a RAR archive) 📖 Manual Coverage Systems Covered Powertrain: Engine (top end, lubrication, removal/installation, crankshaft, transmission), Clutch, Fuel System, Cooling System, Final Drive Chassis: Wheels, Tires, Brakes, Suspension, Steering, Frame Electrical: Complete Electrical System, Wiring Diagrams (implied by 'all information and diagrams') Procedures Included Maintenance: Routine checks, fluid changes, lubrication, filter replacements, tire rotation/replacement, brake pad/shoe replacement, spark plug replacement. Diagnostics: Troubleshooting for all systems, component testing, identifying common issues. Repair Rebuild: Complete engine rebuild procedures, transmission overhaul, suspension component replacement, brake system servicing, electrical component repair. Installation Replacement: Engine removal/installation, component replacement (e.g., clutch, suspension parts, electrical components). Technical Depth Depth Of Coverage: Comprehensive, suitable for dealership technicians, covering detailed disassembly, assembly, adjustments, specifications, and troubleshooting. Diagnostic Procedures: In-depth diagnostic trees and flowcharts for common and complex problems. Torque Specifications: Detailed torque values for all critical fasteners. Wiring Diagrams: Comprehensive electrical wiring diagrams for the entire motorcycle. 📊 Manual Specifications File Format File Format: RAR Archive containing PDF files Required Software: WinRAR or compatible archive extraction software (e.g., 7-Zip), PDF Reader Compatibility: All Versions of Windows & Mac Print Quality Print Quality: High Quality, suitable for printing (PDF) Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Configuration: 90° V-twin, two-stroke Displacement: 249 cc Bore X Stroke: 54 x 54.5 mm Cooling System: Liquid-cooled Valvetrain: Reed valves, Rotary disc valve (Suzuki RG500 derived) Performance Horsepower: Approx. 70-75 hp (depending on market restrictions and tuning) Torque: Approx. 32-34 Nm (24-25 lb-ft) Fuel System Carburetors: Twin 32mm Mikuni TM32SS flat-slide carburetors Fuel Type: Unleaded gasoline (premium recommended), 2-stroke oil injection Lubrication Oil System: Automatic 2-stroke oil injection system Engine Removal Installation Procedure Coverage: Detailed steps for engine removal and installation, including necessary component disconnections and frame clearances. 🔧 Transmission Standard Type: 6-speed constant mesh sequential Features Gear Ratios: Detailed ratios for each gear will be provided in the manual. Clutch Type: Wet multi-plate, cable-actuated Clutch Servicing: Procedures for clutch inspection, adjustment, replacement of friction plates, springs, and pressure plates. 📐 Dimensions Exterior Length: Approx. 2030 mm (79.9 in) Width: Approx. 710 mm (28.0 in) Height: Approx. 1135 mm (44.7 in) Weights Dry Weight: Approx. 140 kg (308.6 lbs) Wet Weight: Approx. 150 kg (330.7 lbs) 🛡️ Safety Features Ratings Safety Ratings: N/A (Motorcycle, typically not subject to automotive safety rating standards like NCAP) Active Features Brakes: Dual front disc brakes (320mm), Single rear disc brake (240mm),...