🏷️ Basic Information Identification Make: Aprilia Model: RS 250 Model Code: RS250 Production Years Covered: 1994-1998 👋 Introduction Market Position Positioning: The Aprilia RS 250 was a highly regarded, lightweight supersport motorcycle known for its performance and racing heritage, often seen as a premium offering in the 250cc class. Competitive Analysis Competitors: Competed directly with models like the Yamaha YZF-R25, Honda CBR250RR, and Suzuki RGV250Gamma during its production run. Key Features Notable Features: Suzuki RGV Gamma-derived parallel-twin two-stroke engine, advanced chassis geometry, aggressive styling, sharp handling characteristics. Target Audience Audience: Enthusiasts, track day riders, and owners seeking to maintain or restore their Aprilia RS 250. 📋 Manual Details Coverage Areas General: Comprehensive service and repair information for the Aprilia RS 250, covering all aspects of maintenance, troubleshooting, and repair. Page Count Estimated Pages: Over 300 pages (typical for this era's detailed service manuals) Manual Type Type: Service and Repair Manual Language Language: English Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Engine: Engine assembly, disassembly, tuning, carburetor adjustment, lubrication, cooling system. Transmission: Gearbox, clutch operation, maintenance, and repair. Chassis: Frame, suspension (front forks, rear shock), steering, wheels, and tires. Brakes: Front and rear brake systems, hydraulic components, pad replacement, fluid bleeding. Electrical: Ignition system, lighting, charging system, battery, wiring diagrams, starter motor, control units. Fuel System: Fuel tank, fuel lines, petcock, fuel pump (if applicable), carburetor tuning and maintenance. Exhaust System: Exhaust pipe and silencer assembly, gasket replacement. Bodywork And Fairings: Fairing removal and installation, body panel repairs, decal placement. Procedures Included Maintenance: Routine checks, lubrication schedules, filter replacements, spark plug service, chain adjustment. Troubleshooting: Diagnostic procedures for common running issues, electrical faults, and mechanical problems. Repair: Step-by-step instructions for component disassembly, repair, and reassembly. Rebuilds: Detailed procedures for engine and transmission overhauls. Technical Depth Depth: Comprehensive, suitable for professional technicians and experienced DIY mechanics. Includes detailed torque specifications, clearances, and diagnostic charts. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable PDF for easy information retrieval. Printable: Yes, designed to be printable for workshop use. Print Quality Quality: High-resolution scans ensuring clarity of text and diagrams. Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 90-degree V-twin, two-stroke Displacement: 249 cc (cubic centimeters) Bore X Stroke: 54 x 54.5 mm (millimeters) Compression Ratio: Approx. 7.1:1 (variable with tuning) Power Delivery: Peaky powerband, characteristic of high-performance two-stroke engines. Performance Horsepower: Approx. 70-75 hp (at crankshaft, depending on market and tuning) Torque: Approx. 28-30 lb-ft (at crankshaft, depending on market and tuning) Fuel System Carburetors: Dual 32mm Mikuni VM32SS or similar (specific model may vary) Fuel Type: Unleaded gasoline, minimum 95 RON (research required for specific octane recommendations) Lubrication Oil System: Premix or Automatic Oil Injection (depending on specific model/market, check VIN) Cooling System Cooling Method: Liquid-cooled 🔧 Transmission Standard Type: 6-speed constant mesh, sequential manual Clutch: Wet multi-plate, cable-actuated Features Gear Ratios: Specific ratios available in the manual, crucial for performance tuning. Final Drive: Chain drive 📐 Dimensions Exterior Length: Approx. 1980 mm (77.9 inches) Width: Approx. 720 mm (28.3 inches) Height: Approx. 1100 mm (43.3 inches) Weights Dry Weight: Approx. 142 kg (313 lbs) Wet Weight: Approx. 157 kg (346 lbs) Fuel Capacity: Approx. 15 liters (3.9 US gallons) 🛡️ Safety Features Ratings Safety Standards: Not subject to typical automotive crash testing; safety is inherent in rider skill and maintenance. Active Features Braking System: Dual front disc brakes (320mm), single rear disc brake (240mm), often with Nissin calipers. Suspension: Fully adjustable front forks (e.g., Showa) and adjustable rear monoshock (e.g., Sachs or similar). Passive Features Lighting: Halogen headlights, LED taillight (depending on market/updates), turn signals. 💡 Technology Features Infotainment Features: N/A - This is a performance-focused sportbike from the 1990s; no advanced infotainment systems. Driver Assistance Features: N/A - No electronic rider aids such as ABS or traction control were standard on this model. 🔧 Maintenance Service Intervals Oil Change: Every 2,000-3,000 km or annually (for gearbox oil); check manual for specific two-stroke oil consumption. Spark Plugs: Check and clean/replace every 4,000-6,000 km. Use correct NGK or equivalent spark plugs (e.g., NGK BR9EG). Air Filter: Inspect every 4,000 km, clean or replace as needed. Use genuine Aprilia or K&N equivalent. Chain Maintenance: Clean and lubricate every 500 km or after riding in wet conditions. Adjust tension as per manual specs. Brake Fluid: Replace every 2 years or as per manual, using DOT 4 or DOT 5.1 brake fluid. Fluid Specifications Coolant: Mixture of distilled water and ethylene glycol-based antifreeze (50/50 ratio recommended). Gearbox Oil: SAE 10W-40 or SAE 15W-50 API GL-4 or GL-5 gear oil. Capacity typically around 0.8 - 1.0 liters. Two Stroke Oil: High-quality JASO FD certified synthetic two-stroke oil, if equipped with automatic injection. Known Issues Carburetor Tuning: Carburetors can be...