🏷️ Basic Information Identification Make: Aprilia Model: RS250 Year: 1996 Product Type: Factory Service Repair Manual 👋 Introduction Market Position Market Position: The Aprilia RS250 was a high-performance, race-inspired sportbike, positioned as a premium offering in the 250cc class, competing with models from Yamaha (TZR250), Suzuki (RGV250), and Honda (NSR250). Competitive Analysis Competitive Analysis: Known for its potent twin-cylinder 2-stroke engine derived from Suzuki's RGV250 Gamma, the RS250 offered exceptional handling, braking, and a distinctive Italian style, appealing to riders seeking track-day performance and spirited road riding. Key Features Key Features: Lightweight chassis, advanced suspension components (like Showa USD forks), powerful twin-cylinder 2-stroke engine, aggressive styling, and competitive performance figures. 📋 Manual Details Coverage Areas Manual Coverage: Comprehensive repair and adjustment information for the Aprilia RS250 1996 model. Page Count Page Count: Estimated 300-400 pages (typical for a factory service manual of this era). Manual Type Manual Type: Factory Service Repair Manual Language Language: English (primary, with potential for localized versions depending on distribution). Format Format: Printed book (original factory output), potentially available as a digital PDF. 📖 Manual Coverage Systems Covered Engine System: Detailed disassembly, assembly, inspection, and repair of the V-twin 2-stroke engine, including cylinder head, pistons, crankshaft, lubrication, cooling, and exhaust systems. Transmission System: Inspection, maintenance, and repair of the gearbox, clutch assembly, shift mechanism, and associated components. Chassis Suspension: Front and rear suspension disassembly, overhaul, and adjustment (forks, rear shock absorber), steering head bearing maintenance. Braking System: Front and rear brake caliper overhaul, master cylinder service, brake line replacement, bleeding procedures, disc inspection. Electrical System: Wiring diagrams, ignition system diagnosis, lighting, battery, charging system, starter motor, instrument cluster troubleshooting. Fuel System: Carburetor service (Mikuni T-series), fuel tank, fuel lines, fuel pump (if applicable), fuel filter maintenance. Cooling System: Radiator service, coolant replacement, water pump inspection, thermostat testing. Exhaust System: Expansion chamber and silencer inspection, maintenance, and removal/installation. Bodywork And Frame: Fairing removal/installation, seat, fuel tank mounting, frame inspection, and cosmetic component repair. Procedures Included Routine Maintenance: Oil changes, chain adjustment, filter cleaning/replacement, spark plug replacement, brake pad inspection, tire pressure checks. Troubleshooting: Diagnostic procedures for common starting, running, and electrical issues, including fault code interpretation (if applicable). Component Rebuild: Detailed instructions for rebuilding carburetors, engine components (pistons, rings), brake calipers, and suspension units. Torque Specifications: Comprehensive list of critical torque values for engine, chassis, and braking components. Diagnostic Flowcharts: Step-by-step guides for diagnosing specific problems with electrical and mechanical systems. Wiring Diagrams: Detailed, accurate wiring diagrams for all electrical circuits. Technical Depth Depth Of Coverage: Factory-level, covering everything from routine maintenance to complete engine and chassis rebuilds. Suitable for professional mechanics and experienced DIY enthusiasts. 📊 Manual Specifications File Format Digital Format: PDF (if available digitally), optimized for clear printing and screen readability. Searchable text is a significant advantage. Print Quality Print Quality: High-resolution scans of original factory manuals, ensuring clarity of diagrams, text, and images. Binding Type Binding Type: Perfect bound or spiral bound for printed versions, allowing the manual to lay flat on a workbench. Paper Type Paper Type: Durable, coated paper stock suitable for workshop environments, resisting grease and dirt. ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 2-stroke, V-twin (90-degree) Displacement: 249 cc Bore X Stroke: 54 mm x 54.5 mm Power Output: Approx. 70-72 hp @ 11,000 rpm (depending on market restrictions) Torque: Approx. 38-40 Nm @ 10,500 rpm Compression Ratio: 7.5:1 Ignition: Digital CDI with dual spark plugs per cylinder Cooling System: Liquid-cooled with fan assist Fuel System Carburetors: Twin Mikuni TM34SS (flat-slide, constant velocity) with T.P.S. (Throttle Position Sensor) on rear carb. Fuel Type: Unleaded gasoline, minimum 95 RON Lubrication System Oil Delivery: Autolube (separate oil injection system) Engine Oil Type: High-performance 2-stroke motorcycle oil, API TC, JASO FD certified (e.g., Motul 7100 2T, Castrol TTS). 🔧 Transmission Standard Transmission Type: 6-speed sequential, constant mesh Clutch Type: Wet multi-plate Gear Ratios: 1st: 2.615 (34/13), 2nd: 1.812 (34/18), 3rd: 1.350 (27/20), 4th: 1.090 (24/22), 5th: 0.956 (22/23), 6th: 0.869 (20/23) Final Drive: Chain drive, 520 pitch 📐 Dimensions Exterior Length: Approx. 1995 mm (78.5 in) Width: Approx. 720 mm (28.3 in) Height: Approx. 1135 mm (44.7 in) Wheelbase: Approx. 1395 mm (54.9 in) Seat Height: Approx. 810 mm (31.9 in) Weights Dry Weight: Approx. 141 kg (310.8 lbs) Wet Weight: Approx. 157 kg (346.1 lbs) Fuel Tank Capacity: 16 liters (4.2 US gal) 🛡️ Safety Features Ratings Safety Ratings: Motorcycles of this era typically did not undergo standardized crash testing like cars. Safety focused on rider control and braking capability. Active Features Braking System: Dual 320mm front discs with 4-piston calipers, single 240mm rear disc with 2-piston caliper. Excellent stopping power for its class. Suspension: Fully adjustable Showa upside-down (USD) front forks (43mm diameter) and Pro-Link rear monoshock, providing precise handling and stability. Passive Features Frame Construction: Lightweight aluminum twin-spar...