🏷️ Basic Information Identification Make: Aprilia Model: RS250 Year: 1995-1997 Codes Vehicle Platform Code: MK1 Generation Generation Identifier: First Generation (RGV500 Derived) 👋 Introduction Market Position Segment: High-performance sportbike, 250cc class. Target Audience: Enthusiasts, racers, and owners seeking to maintain or restore their Aprilia RS250. Competitive Analysis Key Competitors: Yamaha YZF-R6, Honda CBR250RR, Suzuki GSX-R250 (in respective markets). Unique Selling Proposition: Pure 2-stroke performance derived from Grand Prix racing technology (RGV500 heritage), sharp handling, distinctive styling. Key Features Engine Configuration: Liquid-cooled, 90-degree V-twin, 2-stroke Power Delivery: Aggressive, peaky power delivery typical of high-strung 2-strokes, enhanced by electronic power valves. Chassis Design: Twin-spar aluminum frame, renowned for its stiffness and feedback. Suspension Components: Often equipped with premium suspension components (e.g., Showa or Öhlins) from the factory. 📋 Manual Details Coverage Areas Manual Type: Service Repair Workshop Manual Language: English Format: Downloadable Digital File (likely PDF) Page Count Estimated Page Count: High (Detailed Workshop Manuals typically exceed 300 pages) 📖 Manual Coverage Systems Covered Engine System: Complete engine disassembly, assembly, tuning, diagnostics, and component specifications for the 2-stroke V-twin engine. Fuel System: Carburetor tuning (Mikuni T24), fuel pump, fuel lines, fuel tank maintenance and repair. Ignition System: CDI unit, spark plugs, ignition timing, wiring diagrams related to ignition. Cooling System: Radiator, coolant, water pump, hoses, temperature regulation. Transmission System: Gearbox inspection, maintenance, repair, clutch operation, gear shift mechanism. Exhaust System: Expansion chambers, mufflers, installation, maintenance. Chassis Frame: Frame inspection, alignment, modifications, engine mounting. Suspension Front: Öhlins or Showa upside-down forks, internal components, seals, oil levels, adjustments, and overhaul procedures. Suspension Rear: Monoshock absorber (e.g., Öhlins or Showa), linkage system, adjustments, and rebuild. Braking System Front: Brake calipers (e.g., Nissin 4-piston), brake discs, master cylinder, brake fluid, bleeding procedures, pad replacement. Braking System Rear: Brake caliper, brake disc, master cylinder, brake fluid, bleeding procedures, pad replacement. Wheel Tires: Wheel bearing replacement, tire mounting and balancing, wheel specifications. Electrical System: Wiring diagrams, battery, charging system (stator, regulator/rectifier), lighting, instrumentation, starter motor. Bodywork Fairings: Fairing removal and installation, body panel repair and replacement, decal application. Control Cables: Throttle cables, clutch cable, brake cables, adjustments, and replacement. Lubrication System: 2-stroke oil injection system, oil pump calibration, oil tank. Procedures Included Routine Maintenance: Pre-ride checks, oil changes, chain lubrication and adjustment, filter cleaning/replacement. Engine Rebuild: Top-end rebuild (piston, rings, cylinder), bottom-end rebuild (crankshaft, bearings), power valve service, decarbonization. Carburetor Overhaul: Complete disassembly, cleaning, jetting adjustments, float height setting, idle speed adjustment. Suspension Fork Rebuild: Fork seal replacement, oil level adjustment, spring replacement, damping adjustments. Brake System Service: Brake pad replacement, caliper servicing, brake fluid flush and bleed, master cylinder overhaul. Electrical Troubleshooting: Fault finding for starting issues, charging problems, lighting failures using wiring diagrams. Clutch Replacement: Friction plates, steel plates, and spring replacement. Power Valve Adjustment: Calibration and adjustment of the electronically controlled exhaust power valves for optimal performance across the RPM range. Diagnostic Procedures: Troubleshooting guides for common performance issues, starting problems, and abnormal noises. Bodywork Repair: Minor dent repair, crack welding, paint preparation and application advice. Technical Depth Depth Of Coverage: Comprehensive from basic maintenance to full engine and gearbox rebuilds, including detailed troubleshooting and specifications. Diagnostic Capabilities: Detailed troubleshooting flowcharts and symptom-based problem diagnosis. Component Level Repair: Instructions for repairing or replacing individual components within larger assemblies (e.g., individual carburetor jets, fork internals). Specifications Accuracy: Includes critical torque values, clearances, fluid capacities, electrical resistance values, and performance benchmarks. 📊 Manual Specifications File Format File Type: Digital Download (likely PDF) Searchability: Likely OCR'd for text searchability (if a scanned PDF). Print Quality Digital Resolution: Depends on source; professional manuals are typically high-resolution scans or digital originals. Binding Type Binding For Digital: N/A (Digital format) Paper Type Paper Type For Digital: N/A (Digital format) ⚙️ Engine Specifications Primary Engine Engine Type: 90° V-twin, liquid-cooled, 2-stroke, Reed valve induction Bore X Stroke: 54.0 mm x 54.5 mm Displacement: 249 cc Compression Ratio: 7.3:1 (typical for this era) Power Valves: Suzuki's ('APTC') electronically controlled exhaust power valves (RVT - Rotary Valve Timing) Performance Horsepower Peak: Approx. 65-70 HP (at the crank, depending on market restrictions and tuning) Torque Peak: Approx. 40-42 Nm (at the crank) Fuel System Carburetors: 2 x Mikuni T24 (or similar, depending on region) Fuel Type: Unleaded premium gasoline (min 95 RON) Lubrication System 2 Stroke Oil Type: High-quality 2-stroke synthetic oil (e.g., Motul 800, Castrol TTS, Bel-Ray HP Plus) Oil Injection: Automatic oil injection system 🔧 Transmission Standard Transmission Type: 6-speed constant mesh, sequential manual Optional Optional Transmission: N/A (Standard on all RS250 models) Features Clutch Type: Wet, multi-plate, hydraulic actuation Gear Ratios: Specific gear ratios are detailed within the manual, crucial for performance tuning. 📐 Dimensions Exterior Overall Length: Approx. 2000 mm Overall Width: Approx. 710 mm Overall Height: Approx. 1140 mm Wheelbase: Approx. 1375 mm Weights Dry Weight: Approx. 139-145 kg (depending...