🏷️ Basic Information Identification Make: Aprilia Model: RS 250 Model Years Covered: 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002 Codes Internal Model Code: Derived from production chassis codes, specific details often vary by sub-model/year. 👋 Introduction Market Position Segment: Lightweight supersport motorcycle. Target Audience: Performance-oriented riders, track day enthusiasts, and DIY mechanics. Competitive Analysis Rivals: Yamaha YZF-R6, Honda CBR250RR/CBR400RR (depending on market availability), Kawasaki ZXR250/ZZR-400. Key Features Performance Focus: Renowned for its potent V-twin 2-stroke engine and sharp handling. Racing Heritage: Directly derived from Aprilia's successful racing platforms. Manual Value: Essential for maintaining the performance and longevity of a specialized 2-stroke motorcycle. 📋 Manual Details Coverage Areas Primary Coverage: Complete service, repair, and workshop procedures. Secondary Coverage: Maintenance schedules, troubleshooting, diagnostics, component overhaul. Page Count Estimated Page Count: 300-400 pages (typical for comprehensive workshop manuals of this era). Manual Type Type: Workshop Service Repair Manual. Language Language: English (assumed for primary market of this manual). Format Format: Digital (PDF - common for modern re-releases of historical manuals). 📖 Manual Coverage Systems Covered Engine: Complete overhaul, tuning, lubrication, cooling, ignition, fuel delivery (carburetor specific), exhaust. Transmission: Clutch operation, gearbox disassembly and reassembly, shift mechanism, lubrication. Chassis: Frame inspection, steering head bearings, suspension (front forks, rear shock absorber), swingarm, wheel bearings. Brakes: Front and rear brake systems, caliper overhaul, master cylinder, brake fluid, bleeding procedures, disc inspection. Electrical: Wiring diagrams, lighting system, ignition system components, battery, charging system (stator, regulator/rectifier), instrumentation. Bodywork: Fairing removal and installation, seat, fuel tank, minor body panel repairs. Procedures Included Routine Maintenance: Oil changes, filter replacements, chain adjustment and lubrication, spark plug checks, air filter cleaning/replacement. Troubleshooting: Diagnostic flowcharts for common engine performance issues, electrical faults, and handling problems. Component Overhaul: Detailed step-by-step instructions for rebuilding the engine (top-end and bottom-end), carburetors, brake calipers, and suspension components. Technical Specifications: Torque values for critical fasteners, engine specifications, electrical system data, fluid capacities. Technical Depth Depth: Comprehensive from basic maintenance to complete engine rebuilds and electrical system troubleshooting. 📊 Manual Specifications File Format Format Details: Searchable PDF for easy navigation and keyword finding. Printable pages. Print Quality Quality: High-resolution scans of original diagrams and text for clarity. Binding Type Binding: N/A (Digital Format). Paper Type Paper: N/A (Digital Format). ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 2-stroke, V-twin. Displacement: 249 cc. Bore X Stroke: 54 mm x 54.5 mm (approximate). Compression Ratio: 12.1:1 (approximate). Induction: Dual 32 mm Dell'Orto PHBH carburetors. Ignition: Electronic CDI (Capacitor Discharge Ignition). Lubrication: Pre-mix or separate oil injection system (check model year specifics). Performance Horsepower: Approx. 70-75 HP at the crank (depending on market and tuning). Torque: Approx. 40-45 Nm (depending on market and tuning). Fuel System Fuel Type: Unleaded gasoline (95 RON or higher recommended). Fuel Tank Capacity: Approx. 16 liters. 🔧 Transmission Standard Type: 6-speed constant mesh. Optional Options: N/A (Standard 6-speed gearbox). Features Clutch: Wet multi-plate clutch. Final Drive: Chain drive. 📐 Dimensions Exterior Length: Approx. 1970 mm. Width: Approx. 720 mm. Height: Approx. 1100 mm. Wheelbase: Approx. 1385 mm. Weights Dry Weight: Approx. 143 kg. Wet Weight: Approx. 157 kg (fully fuelled). 🛡️ Safety Features Ratings Crash Safety: Not applicable for motorcycles in the same manner as cars. Focus is on rider protection and vehicle stability. Active Features Braking: Dual front discs (e.g., 320mm) with radial-mount calipers, single rear disc (e.g., 220mm) with conventional caliper. Suspension: Adjustable front forks (e.g., Showa or Marzocchi), adjustable rear monoshock absorber. Passive Features Riding Position: Aggressive, forward-leaning sportbike ergonomics. Chassis Design: Aluminum twin-spar frame for rigidity and light weight. 💡 Technology Features Infotainment Features: N/A (This era of sportbike focused on mechanical performance, not infotainment). Driver Assistance Features: N/A (No electronic rider aids like ABS or traction control were standard). Connectivity Features: N/A (No electronic connectivity features). 🔧 Maintenance Service Intervals Oil Change Engine: Every 3,000 - 5,000 km or annually (refer to manual for specific recommendations). Spark Plug Check: Every 5,000 - 7,500 km. Air Filter Cleaning: Every 5,000 km or as needed based on operating conditions. Chain Maintenance: Lubrication and adjustment every 500-1000 km or after riding in wet conditions. Fluid Specifications Engine Oil: 2-stroke pre-mix or injection oil meeting JASO FD or API TC specifications (specific viscosity grade, e.g., 10W-40, might be specified). Coolant: Ethylene glycol-based antifreeze mixed with distilled water (50/50 ratio recommended). Brake Fluid: DOT 4 recommended. Gearbox Oil: SAE 75W-90 or SAE 80W-90 API GL-4 or GL-5 (refer to manual for exact specification). Known Issues Power Valve Sticking: Common in 2-strokes; requires regular cleaning and lubrication of the exhaust power valve mechanism. Carburetor Synchronization And Cleaning: Dell'Orto carbs can be finicky; require periodic synchronization and cleaning for optimal performance. Clutch Wear: Can be accelerated by aggressive riding; clutch plates and springs may need replacement. Electrical Connections: Corrosion or loose connections, especially in the charging system, can...