The Aprilia RS 250 Challenge Version, produced between 1995 and 2004, is a high-performance sportbike renowned for its exceptional handling and potent two-stroke V-twin engine, derived from Suzuki RGV250 Gamma components. This model, often prepared for track use, embodies Aprilia's rich racing heritage and Italian engineering prowess. Its lightweight aluminum twin-spar frame, powerful braking system, and responsive chassis contribute to its reputation as a premier 250cc sportbike of its era, offering an engaging and pure riding experience focused on mechanical feedback and rider skill. This comprehensive service manual provides in-depth technical features and servicing procedures for the Aprilia RS 250 Challenge Version, covering a wide array of systems including the fuel, cooling, engine, clutch, lubrication, transmission, wheels, tires, brakes, suspension, steering, frame, and electrical systems. It details routine maintenance, fluid changes, and detailed repair and diagnostic instructions for all major components, offering professional-level guidance equivalent to dealership technician manuals. This resource is essential for owners and technicians aiming to maintain the optimal performance and longevity of this specialized sportbike. 🏷️ Basic Information Identification Make: Aprilia Model: RS 250 Challenge Version Codes Engine Code: RS 250 Challenge (Likely derived from Suzuki RG500 Gamma components) 👋 Introduction Market Position Target Audience: Aprilia RS 250 Challenge Version owners and technicians requiring in-depth service and repair information. Competitive Analysis Value Proposition: Provides dealership-level technical data, enabling users to perform complex maintenance and repairs, saving time and costs associated with professional servicing. Crucial for maintaining the performance and longevity of a specialized sportbike. Key Features Manual Utility: Comprehensive instructions and diagrams for high-quality repairs, facilitating understanding and efficient problem-solving. Acts as a professional reference book for bike maintenance. 📋 Manual Details Coverage Areas Primary Coverage: Technical features and servicing procedures for the Aprilia RS 250 Challenge Version (USA). Page Count Estimated Page Count: Unknown (Based on typical workshop manuals, likely several hundred pages) Manual Type Type: Service Manual / Repair Manual Language Language: English Format Format: PDF Download (within a RAR archive) 📖 Manual Coverage Systems Covered Engine Systems: Fuel System, Cooling System, Engine Top End, Clutch, Engine Lubrication System, Engine Removal/Installation, Crankshaft/Transmission, Carburetor Assembly, Fuel Pump, Fuel Filter, Air Filter Chassis Systems: Wheels/Tires, Final Drive, Brakes, Suspension, Steering, Frame, Electrical System Procedures Included Maintenance Procedures: Routine maintenance, oil changes, fluid changes, tire rotation, brake pad replacement, air filter replacement. Repair Procedures: Comprehensive instructions for fixing problems, detailed diagnostics and repair of all major systems. Technical Depth Depth: Professional level, equivalent to dealership technician manuals, covering everything from basic servicing to detailed repair and diagnosis. 📊 Manual Specifications File Format Download Package: RAR archive, requires WinRAR or compatible extraction software. Document Format: PDF Print Quality Printability: Assumed to be printable due to PDF format, intended for professional use, implying good clarity of diagrams and text. Binding Type Binding: N/A (Digital download) Paper Type Paper Type: N/A (Digital download) ⚙️ Engine Specifications Primary Engine Engine Type: Two-stroke, V-twin Performance Displacement: 249 cc Bore X Stroke: 54 mm x 54.5 mm Horsepower Estimate: Approx. 70-75 HP (stock, depending on year and market) Torque Estimate: Approx. 42 Nm (stock) Fuel System Carburetion: Dual 32mm Mikuni TMR carburetors (typical for Challenge Version) Fuel Type: Unleaded gasoline (high octane recommended) Engine Lubrication Lubrication Type: Premix or Autolube (check specific model variant, autolube is common) 🔧 Transmission Standard Type: 6-speed constant mesh Features Clutch Type: Wet, multi-plate Final Drive: Chain driven 📐 Dimensions Weights Dry Weight: Approx. 140 kg Wet Weight: Approx. 165 kg (fully fueled) Exterior Length Overall: Approx. 1980 mm Width Handlebar: Approx. 720 mm Height Seat: Approx. 810 mm Wheelbase: Approx. 1385 mm 🛡️ Safety Features Ratings Safety Features Overview: Focus on rider control and braking; no electronic rider aids like ABS or traction control typically found on this model. Active Features Braking System: Dual front discs (e.g., 320mm) with 4-piston calipers, single rear disc with 2-piston caliper. Often featuring Brembo components. Passive Features Frame Design: Aluminum twin-spar frame for rigidity and handling. 💡 Technology Features Infotainment Dashboard Instruments: Analog tachometer, speedometer, coolant temperature gauge, and indicator lights. Driver Assistance Rider Aids: None; this is a pure performance sportbike focused on mechanical feedback and rider skill. Connectivity Connectivity Features: N/A 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 3,000-5,000 km or annually, depending on usage. Transmission oil change every 6,000-10,000 km. Spark Plug Replacement: Every 6,000-8,000 km (or as per manual specification, type NGK BR9EG or similar). Fluid Specifications Coolant Type: Ethylene glycol based antifreeze/coolant, 50/50 mix with distilled water. Brake Fluid Type: DOT 4 or DOT 5.1 (check manual for specific recommendation). Transmission Oil Type: SAE 10W-40 or 15W-50 motorcycle-specific gear oil (check manual for exact API GL rating and viscosity). Known Issues Common Wear Items: Clutch plates, exhaust valve mechanism (if equipped), crankcase seals, ignition coils, carburetor synchronization. Two Stroke Specific Concerns: Proper oil-fuel mixture,...