🏷️ Basic Information Identification Make: Aprilia Model: RS250 Motorcycle Type: Sportbike Production Years Covered By Manual: 1995, 1996, 1997 Codes Chassis Codes: AP81000 series (specific VIN range dependent) Engine Codes: Rotax 257 (2-stroke V-twin) 👋 Introduction Market Position Segment: Lightweight, high-performance two-stroke sportbike. Target Audience: Enthusiasts, track day riders, and those seeking a classic performance motorcycle. Competitive Analysis Key Competitors Era: Yamaha YZF-R6, Suzuki GSX-R600, Kawasaki Ninja ZX-6R (though the RS250 occupied a unique niche due to its two-stroke engine). Key Features Engine Configuration: 2-stroke, V-twin, liquid-cooled – a defining characteristic and significant performance advantage. Performance Focus: Lightweight chassis, powerful two-stroke engine delivering excellent power-to-weight ratio. Handling: Renowned for sharp, precise handling and agility. 📋 Manual Details Coverage Areas Coverage Scope: Complete Service and Repair Specific Systems: Engine, Transmission, Electrical, Fuel System, Cooling System, Chassis, Suspension, Brakes, Bodywork, Troubleshooting Page Count Estimated Page Count: Highly comprehensive, likely 300+ pages (actual count not specified, but description implies full coverage) Manual Type Manual Type: Official Factory Service & Repair Manual Language Language: English (assumed standard for official manuals of this era, confirmation recommended) Format Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Complete overhaul, cylinder head, pistons, connecting rods, crankshaft, lubrication system, cooling system (radiator, water pump), exhaust system. Fuel System: Carburetor (Mikuni TMX), fuel pump, fuel tank, fuel lines, petcock. Ignition System: CDI ignition, spark plugs, ignition coils, wiring diagrams. Transmission And Drivetrain: Clutch, gearbox (6-speed), final drive (chain and sprockets), shifting mechanism. Electrical System: Battery, charging system (alternator, regulator/rectifier), lighting, instrumentation, starter motor, wiring harnesses, fuses, ECU. Chassis And Suspension: Frame, front fork (upside-down), rear shock absorber, swingarm, steering head bearings. Brakes: Front and rear hydraulic disc brakes, master cylinders, calipers, brake lines, pad replacement, bleeding procedures. Wheels And Tires: Wheel bearing replacement, tire fitment, pressure specifications. Bodywork: Fairing removal and installation, seat, fuel tank, other body panels. Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, chain adjustment, brake adjustments, fluid checks. Repair: Complete engine rebuild, gearbox repair, suspension overhaul, brake system servicing, electrical component replacement. Troubleshooting: Diagnostic procedures for common problems, fault finding based on symptoms, electrical diagnostics, engine performance issues. Diagnostics: Step-by-step diagnostic flowcharts for various systems. Assembly Disassembly: Detailed tear-down and reassembly instructions for all major components. Technical Depth Depth Of Coverage: Comprehensive, covering all aspects from basic maintenance to full engine rebuilds and advanced diagnostics. Diagrams And Illustrations: Includes pictures and part diagrams for clarity. Torque Specifications: Detailed torque values for all critical fasteners. Wiring Diagrams: Provided for the electrical system. 📊 Manual Specifications File Format File Type: PDF Searchable Text: Typically yes for PDF, allowing easy keyword searching (confirmation recommended). Print Quality Print Readability: High quality, designed for clear viewing of text and diagrams. Binding Type Binding: N/A (Digital PDF format) Paper Type Paper Quality: N/A (Digital PDF 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 Power Output: Approx. 70-74 hp @ 11,000 rpm (varies by region and specific tune) Torque Output: Approx. 40 Nm (29.5 lb-ft) @ 10,000 rpm (varies by region and specific tune) Compression Ratio: Approx. 7.5:1 (depending on specific engine variant) Cooling System: Liquid-cooled Performance Redline: 12,000 rpm Cylinder Arrangement: 60-degree V-twin Fuel System Carburetion: Dual Mikuni TMX30 flat-slide carburetors Fuel Delivery: Gravity feed with electric fuel pump (later models might differ slightly). Fuel Type: Unleaded gasoline (minimum 95 RON recommended) Oil Mixing: Premix (or Autolube system depending on market/variant, manual will specify) 🔧 Transmission Standard Transmission Type: Constant-mesh 6-speed Clutch Type: Wet multi-plate Final Drive: Chain drive Features Gear Ratios: Specific ratios are detailed in the manual, crucial for performance tuning. Transmission Oil Type: Specific motorcycle gear oil (e.g., SAE 80W/90) – manual will specify exact type and capacity. 📐 Dimensions Exterior Length: Approx. 1950 mm Width: Approx. 710 mm Height: Approx. 1130 mm Wheelbase: Approx. 1370 mm Weights Dry Weight: Approx. 142 kg (significantly lighter than comparable 4-strokes) Wet Weight: Approx. 155 kg (with fluids) Fuel Capacity: 16 Liters (including reserve) 🛡️ Safety Features Ratings Safety Certification: N/A (Motorcycle safety standards vary by region and time; manual focuses on mechanical safety.) Active Features Braking System: Dual 320mm front discs with 4-piston calipers, single 220mm rear disc with 2-piston caliper. Excellent stopping power. Suspension: Adjustable front forks and rear monoshock for optimal handling and stability. Passive Features Frame Construction: Aluminum twin-spar frame for rigidity and light weight. Lighting: Halogen headlight, taillight, turn signals. 💡 Technology Features Infotainment Instrumentation: Analog tachometer, speedometer, odometer, trip meter, and basic indicator lights. No advanced infotainment features typical of modern bikes. Driver Assistance Electronic Aids: None (e.g., no ABS, traction control, or riding modes). 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,000 - 5,000 km or annually (manual will provide precise intervals). Spark Plug Replacement: Refer to manual...