🏷️ Basic Information Identification Make: Aprilia Model: RS250 Vehicle Type: Sportbike Engine Type: Two-stroke V-twin Production Years Covered By Manual: 1995-2004 (indicative, based on common RS250 production run) Codes Engine Code Common: Rotax 257 (variant) Chassis Code Common: RS250 MK1, RS250 MK2 👋 Introduction Market Position Segment: High-performance 250cc two-stroke sportbike Target Audience: Enthusiasts, track day riders, experienced DIY mechanics Competitive Analysis Key Competitors: Yamaha YZF-R25, Honda CBR250RR (earlier generations), Kawasaki ZXR250, Suzuki RG250 Gamma Key Features Performance Focus: Lightweight, agile handling, potent two-stroke power delivery Racing Heritage: Derived from Aprilia's successful Grand Prix racing technology Manual Value Proposition: Enables owners to maintain and repair a technically complex and sought-after motorcycle 📋 Manual Details Coverage Areas Primary Coverage: Maintenance, Service, Diagnosis, Repair Specific Focus: Factory procedures, official specifications Page Count Estimated Page Count: 300-500 (typical for comprehensive factory service manuals) Manual Type Type: Factory Service Manual / Workshop Manual / Repair Manual Language Language: English (common for international service manuals) Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Engine: Engine assembly, disassembly, tuning, cooling system, lubrication system, carburetion, exhaust system, ignition system, starting system Transmission: Gearbox assembly, disassembly, clutch, final drive (chain and sprockets) Chassis: Frame, swingarm, suspension (front forks, rear shock), steering system Brakes: Front and rear brake systems, hydraulic components, caliper service, master cylinder service, bleeding procedures Electrical: Wiring diagrams, lighting system, charging system (stator, regulator/rectifier), battery, starter motor, instrumentation, sensors Fuel System: Fuel tank, fuel lines, fuel pump (if applicable), carburetor adjustment and overhaul Bodywork: Fairings, seat, fuel tank cover, body panel removal and installation Procedures Included Maintenance Tasks: Scheduled maintenance, oil changes, filter replacements, chain adjustment, spark plug replacement, brake fluid replacement, coolant flush Diagnostic Procedures: Troubleshooting guides, symptom-based diagnostics, fault finding for electrical and mechanical issues Repair Procedures: Step-by-step instructions for component removal, replacement, and reassembly Adjustment Procedures: Carburetor synchronization, ignition timing, chain slack, suspension settings Special Tools: Identification and use of specialized tools required for specific procedures Technical Depth Depth: Comprehensive; covers basic maintenance to full engine rebuilds and complex electrical diagnostics Level Of Detail: Detailed diagrams, torque specifications, measurements, clearances 📊 Manual Specifications File Format File Format: PDF (Portable Document Format) Searchability: Text-searchable (typically, for PDFs derived from digital sources) Print Quality Print Quality: High resolution, suitable for printing individual pages or the entire document Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Configuration: V-twin, two-stroke Displacement: 249 cc (approx.) Bore X Stroke: 51.7 mm x 60 mm (approx.) Cooling System: Liquid-cooled Power Output Hp: Approx. 65-70 HP (varies by market and specific model year) Torque Nm: Approx. 35-40 Nm (varies) Performance Top Speed: Over 150 mph (240 km/h) Fuel System Carburetor Type: Twin Mikuni T25D (often T25D2 or similar variants) Fuel Delivery: Pre-mix or Oil Injection System (depending on model variant/market) Fuel Type Recommended: 95-98 RON (unleaded gasoline) 🔧 Transmission Standard Type: 6-speed constant mesh Clutch Type: Wet multi-plate Features Gear Ratios: Specific gear ratios will be detailed within the manual Final Drive: Chain-driven 📐 Dimensions Exterior Wheelbase: Approx. 1360-1370 mm (varies slightly by model year) Seat Height: Approx. 810-820 mm Weights Dry Weight: Approx. 141-145 kg 🛡️ Safety Features Ratings Certification: CE, TUV (market dependent) Active Features Braking System Front: Dual 320 mm discs, 4-piston calipers (e.g., Brembo) Braking System Rear: Single 220 mm disc, 2-piston caliper Suspension Front: Inverted telescopic forks (e.g., Marzocchi, Showa) with adjustable preload, compression, and rebound damping Suspension Rear: Monoshock with adjustable preload and damping Passive Features Lighting: Halogen headlight, LED tail light (later models) 💡 Technology Features Infotainment System: N/A (performance-focused sportbike, minimal electronics) 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,000-5,000 km or annually (refer to manual for specific recommendations) Spark Plug Replacement: Every 5,000-7,000 km (refer to manual for exact type and gap) Chain Lubrication Adjustment: Every 500-1000 km or after riding in wet conditions Fluid Specifications Engine Oil Type: High-quality 2-stroke motorcycle oil (e.g., Castrol TTS, Motul 710 2T) - specific grade in manual Coolant Type: Ethylene glycol-based antifreeze coolant (50/50 mix with distilled water) Brake Fluid Type: DOT 4 Transmission Oil Type: Specific gear oil grade (e.g., SAE 75W-90 or 10W-40, refer to manual) Known Issues Common Problems A: Carburetor jetting issues leading to bogging or poor throttle response, especially at altitude or with aftermarket pipes. Common Problems B: Power valve fouling or sticking, impacting engine performance and leading to rough running. Common Problems C: Crankshaft seal leaks leading to increased oil consumption or engine seizure if not addressed. Common Problems D: Ignition system components (CDI, coil) failure, causing intermittent or no spark. Common Problems E: Wear on the aluminum cylinder bore and piston due to the demanding nature of 2-stroke engines. 📚 Vehicle History Brand Heritage Brand Focus: Aprilia is an Italian manufacturer with a strong...