🏷️ Basic Information Identification Make: Aprilia Model: RS250 Codes Engine Code: Rotary Valve Two-Stroke V-Twin (Based on Suzuki RGV250 Gamma) 👋 Introduction Market Position Class: High-performance 250cc two-stroke sportbike. Competitive Analysis Competitors: Suzuki RGV250 Gamma, Yamaha TZR250, Kawasaki KR-1S. Key Features Engine Design: V-twin, liquid-cooled, two-stroke engine derived from Suzuki RGV250 technology. Chassis Design: Lightweight aluminum twin-spar frame, advanced suspension and braking components. Racing Heritage: Developed with input from Aprilia's racing programs, offering race-bred performance. 📋 Manual Details Coverage Areas Applicable Years: 1994, 1995, 1996, 1997, 1998 Page Count Estimated Page Count: ~300-400 pages (estimated based on professional service manual typicality) Manual Type Type: Official Factory Service & Repair Manual Language Language: English Format Format: Printed Book 📖 Manual Coverage Systems Covered Engine: Complete engine overhaul, disassembly, assembly, tuning, lubrication, cooling system. Fuel System: Carburetor tuning and rebuild (Mikuni VM28SS), fuel pump, fuel lines, fuel tank. Ignition System: CDI ignition, spark plugs, coils, wiring diagrams. Transmission: Gearbox inspection, disassembly, assembly, clutch operation, chain drive maintenance. Brakes: Front and rear brake systems (including Nissin components), hydraulic system, bleeding procedures, pad replacement, caliper service. Suspension: Front fork (upside-down) disassembly, assembly, oil changes, seals. Rear monoshock adjustment and service. Electrical System: Wiring diagrams, lighting, instrumentation, battery, starter, charging system. Chassis And Bodywork: Frame inspection, fairing removal and installation, seat, handlebars, footpegs. Cooling System: Radiator, hoses, coolant type and capacity. Exhaust System: Expansion chambers, silencer maintenance. Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, chain adjustment, spark plug checks. Troubleshooting: Diagnostic procedures for common problems, symptom-based troubleshooting guides. Repair: Step-by-step repair instructions for all major components and systems. Rebuilds: Complete engine rebuild procedures, carburetor overhauls, suspension rebuilds. Adjustments: Carburetor idle speed and mixture, chain slack, suspension settings, brake lever free play. Technical Depth Depth: Comprehensive: Covers basic maintenance to full engine rebuilds, including detailed diagnostics and component-level repair. 📊 Manual Specifications File Format Print Quality: High-resolution print suitable for professional workshop use. Binding Type Binding: Durable perfect binding or comb binding, designed for workshop use and to lay flat. Paper Type Paper Quality: Heavy-duty, grease-resistant paper to withstand workshop conditions. ⚙️ Engine Specifications Primary Engine Type: Liquid-cooled, 90-degree V-twin, two-stroke Displacement: 249.0 cc (15.19 cubic inches) Bore X Stroke: 54.0 mm x 54.5 mm Valvetrain: Reed valve induction, Rotary Valve (RV) intake system Compression Ratio: 7.4:1 (approx.) Performance Horsepower: ~70-75 HP @ 11,000 RPM (stock, depending on market restrictions) Torque: ~40 Nm (approx.) Fuel System Carburetors: 2 x Mikuni VM28SS, flat slide Fuel Delivery: Oil injection (automatic premix) for lubrication. Engine Components Cylinder Material: Aluminum alloy with Nikasil coating. 🔧 Transmission Standard Type: 6-speed sequential manual gearbox Features Clutch: Wet multi-plate clutch Final Drive: Chain drive 📐 Dimensions Exterior Length: Approx. 1975 mm (77.8 inches) Width: Approx. 720 mm (28.3 inches) Height: Approx. 1130 mm (44.5 inches) Wheelbase: Approx. 1370 mm (53.9 inches) Weights Dry Weight: Approx. 142 kg (313 lbs) Wet Weight: Approx. 156 kg (344 lbs) Fuel Capacity Fuel Tank Capacity: 16 Liters (4.2 US gallons) 🛡️ Safety Features Ratings Certification: Designed for track and street use, meeting relevant safety standards for its class. Active Features Braking System: Dual 320mm front discs with 4-piston Nissin calipers, single 240mm rear disc with 2-piston caliper. Suspension Control: Adjustable front forks (preload, rebound damping) and rear monoshock (preload, rebound damping). Passive Features Frame Construction: Lightweight, high-strength aluminum twin-spar frame for chassis rigidity. 💡 Technology Features Infotainment Instrumentation: Analog tachometer, speedometer, coolant temperature gauge, indicator lights (neutral, turn signals, oil level, high beam). Driver Assistance Electronic Aids: None. This is a pure, analog performance motorcycle from the 1990s. ABS, traction control, or ride modes were not features. 🔧 Maintenance Service Intervals Oil Change: Every 3,000-5,000 km or annually, depending on usage. Engine oil change intervals are crucial for two-strokes. Spark Plugs: Check/replace every 3,000-6,000 km, dependent on plug type and condition. Chain Maintenance: Clean and lubricate every 500-1000 km, adjust chain slack as needed. Fluid Specifications Engine Oil Type: High-quality 2-stroke premix oil (e.g., Castrol TTS, Motul 2T Factory Line) for the oil injection system. Ensure correct API TC or JASO FD rating. For gearbox, use SAE 80W-90 gear oil. Coolant Type: Ethylene glycol-based antifreeze/coolant mixture (50/50) with corrosion inhibitors. Capacity: Approx. 1.2 Liters. Brake Fluid: DOT 4 or DOT 5.1 brake fluid. Known Issues Power Valve Sticking: Common issue in two-strokes; carbon buildup can cause power valves to stick, affecting performance. Requires regular cleaning. Carburetor Tuning: Mikuni VM28SS carburetors require precise tuning, especially after modifications or when using different fuel/exhaust systems. Jetting charts are essential. Exhaust Leaks: Expansion chamber seals and header pipe connections can develop leaks, impacting performance. Ignition Coil Failure: While less common, ignition coils can degrade over time. 📚 Vehicle History Brand Heritage Heritage: Aprilia is an Italian manufacturer with a strong lineage in motorcycle racing, particularly in Grand Prix and...