🏷️ Basic Information Identification Make: Aprilia Model: RS250 Year: 1995-1997 Codes Chassis Code: AP801000 Engine Code Prefix: AP060 👋 Introduction Market Position Class: Lightweight Supersport / Two-Stroke Performance Motorcycle Target Audience: Enthusiasts, sport riders, track day participants, those seeking high-performance, lightweight motorcycles. Competitive Analysis Key Competitors: Yamaha YZF-R6, Suzuki GSX-R600 (early models), Honda CBR600F (early models), Kawasaki ZX-6R (early models), Ducati 750SS, other European 250cc and 400cc performance bikes. Key Features Engine Type: Liquid-cooled, 90-degree V-twin, two-stroke, reed valve induction Performance Focus: High revving, potent power band, agile handling, excellent power-to-weight ratio. Chassis Design: Aluminium twin-spar frame, advanced suspension and braking components, aerodynamic fairing. 📋 Manual Details Coverage Areas Primary Coverage: Complete service and repair for Aprilia RS250 models 1995-1997 Engine Coverage: Engine assembly, disassembly, tuning, cooling, lubrication, fuel, exhaust Chassis Coverage: Frame, suspension, steering, wheels, brakes, bodywork Electrical Coverage: Ignition, lighting, charging system, wiring diagrams, sensors Page Count Estimated Pages: Approximately 250-350 pages (typical for comprehensive service manuals) Manual Type Type: Service and Repair Manual Professional Level: Workshop-grade, technician-level Language Language: English (assumed, based on product description) Format Format: Printed Manual (implied by 'bike repair shop' use) 📖 Manual Coverage Systems Covered Engine Systems: 2-stroke reed valve induction, SV engine principles, cylinder head, piston, crankshaft, connecting rod, lubrication, cooling system (liquid), fuel injection (if applicable to specific sub-models), carburetion (Dell'Orto PHBH 28 or similar), exhaust system (expansion chambers) Transmission Systems: 6-speed constant mesh gearbox, clutch operation (wet multi-plate), gear shift mechanism, final drive (chain) Braking Systems: Front: Dual hydraulic disc brakes with Brembo calipers (e.g., 4-piston opposed type), Rear: Single hydraulic disc brake with Brembo caliper. Brake fluid specifications (DOT 4). Suspension Steering Systems: Front: Inverted telescopic forks (e.g., Marzocchi or Showa, adjustable preload, compression, rebound), Rear: Monoshock swingarm suspension (e.g., Sachs or Ohlins, adjustable preload, rebound, compression). Steering head bearing maintenance and adjustment. Electrical Systems: CDI ignition system, starter motor, battery specifications (e.g., 12V, YTX9-BS), lighting circuits (headlamp, tail lamp, indicators), charging system (alternator, regulator/rectifier), wiring diagrams with component identification. Fuel System: Fuel tank capacity, fuel line routing, carburetor synchronization, jetting specifications, fuel petcock operation. Bodywork Fairings: Fairing removal and installation, seat, fuel tank, side panels, tail section, front fender, rear fender. Procedures Included General Maintenance: Pre-ride inspections, cleaning, lubrication, filter replacement (air and oil, if applicable), chain adjustment and lubrication. Engine Rebuild: Top-end overhaul (piston, rings, cylinder), bottom-end overhaul (crankshaft, bearings), valve clearance adjustment (if applicable, though typically 2-strokes don't have valves), decarbonization. Suspension Service: Fork seal replacement, fork oil change and level adjustment, rear shock absorber servicing and adjustment, linkage lubrication. Brake Service: Brake pad replacement, caliper overhaul, master cylinder service, brake line bleeding and replacement, rotor inspection and replacement. Electrical Troubleshooting: Diagnostic procedures for ignition system faults, charging system issues, lighting failures, starter motor problems, wiring harness inspection. Carburetor Tuning: Carburetor removal, cleaning, reassembly, jetting adjustments for altitude and modifications, idle speed and mixture adjustment. Wheel Tire Service: Tire changing, wheel balancing, spoke tension adjustment, wheel bearing replacement. Technical Depth Diagnostic Capabilities: Detailed troubleshooting guides for common and uncommon problems, symptom-based diagnostics. Repair Procedures: Step-by-step instructions for virtually all mechanical and electrical repairs, from minor adjustments to complete engine rebuilds. Specifications Tolerances: Precise torque specifications for fasteners, critical component clearances, engine timing data, electrical resistance values. 📊 Manual Specifications File Format Digital Format: PDF (most common for digital versions, though original may be printed) Print Quality Original Print: High quality, durable paper stock, clear diagrams and illustrations Digital Readability: Searchable text, zoomable images, printable pages (if well-scanned/formatted) Binding Type Original Binding: Likely perfect bound or saddle-stitched for workshop use Paper Type Original Paper: Heavy-duty, often glossy or semi-gloss for durability and image clarity ⚙️ Engine Specifications Primary Engine Configuration: 90-degree V-twin, two-stroke Displacement: 249 cc Bore X Stroke: 54.0 mm x 54.5 mm Cooling System: Liquid-cooled Valvetrain: Reed valve induction Performance Horsepower: Approximately 65-70 HP (varies slightly by market and specific tune) Torque: Approximately 40-45 Nm Redline: Around 11,500 RPM Fuel System Carburetors: Twin Dell'Orto PHBH 28 (or equivalent Japanese carburetors on some variants) Fuel Type: Unleaded gasoline (95-98 RON) Oil Mixing: Automatic oil injection system (Autolube) Oil Type Injection: 2-stroke synthetic injection oil (e.g., Motul 2T, Castrol TTS) 🔧 Transmission Standard Gearbox: 6-speed, constant mesh Clutch: Wet, multi-plate, cable-actuated Features Gear Ratios: Specific ratios detailed within manual (e.g., 1st: 2.615, 2nd: 1.789, 3rd: 1.400, 4th: 1.182, 5th: 1.045, 6th: 0.958) Final Drive: Chain drive, 520 O-ring chain Transmission Oil Type: API GL-4, SAE 80W/90 transmission oil (specific capacity in manual) 📐 Dimensions Exterior Length: Approx. 1995 mm Width: Approx. 710 mm Height: Approx. 1115 mm Wheelbase: Approx. 1365 mm Weights Dry Weight: Approx. 140 kg Wet Weight: Approx. 155 kg (fully fueled and ready to ride) Fuel Tank Capacity: Approx. 16 liters Wheels Tires Front Tire Size: 120/70-17 Rear Tire Size: 160/60-17 Wheel Type:...