🏷️ Basic Information Identification Make: Aprilia Model: RS250 Generation Generation Code: MK1 Codes Chassis Code: AP80100 👋 Introduction Market Position Category: Performance Sportbike Segment: 250cc Two-Stroke Supersport Competitive Analysis Rivals: Honda NSR250R, Yamaha TZR250, Kawasaki KR-1S Key Features Unique Selling Points: Directly derived from Suzuki RG-V Gamma racing technology, potent two-stroke engine, sharp handling, aggressive styling. 📋 Manual Details Coverage Areas Years Covered: 1994, 1995, 1996, 1997 Page Count Estimated Page Count: 300-400 Manual Type Type: Workshop Repair Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Complete engine assembly, top-end, bottom-end, cooling, lubrication, fuel system, ignition system, exhaust system, power valve system. Transmission: Gearbox operation, clutch assembly, shift mechanism, lubrication, maintenance, troubleshooting. Chassis And Frame: Frame inspection, front fork assembly, rear shock absorber, swingarm, steering head bearings, wheel bearings. Brakes: Front and rear brake systems, caliper maintenance, master cylinder overhauls, hydraulic lines, bleeding procedures, pad replacement. Electrical System: Wiring diagrams, lighting, ignition system components, charging system, battery, starter motor, fuses, relays, diagnostic indicators. Bodywork And Fittings: Fairing removal and installation, seat, fuel tank, handlebars, footpegs, body panel alignment, cosmetic repairs. Cooling System: Radiator, water pump, thermostat, coolant flow, bleeding procedures. Lubrication System: Oil pump, oil lines, oil tank, mixture ratios, oil filter (if applicable). Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacement, chain adjustment, spark plug replacement, carburetor synchronization, coolant flush. Troubleshooting: Diagnostic charts, common problems, symptom-based troubleshooting for engine, electrical, and mechanical issues. Repair: Detailed step-by-step repair procedures for all major mechanical and electrical components, including engine rebuilds, transmission overhauls, and suspension work. Disassembly Assembly: Comprehensive instructions for taking apart and reassembling all components and systems. Engine Tuning: Carburetor tuning, jetting specifications, power valve adjustment procedures. Suspension Setup: Front fork oil level and viscosity, rear shock preload and damping adjustments, general suspension geometry settings. Technical Depth Depth: Full workshop-level detail, suitable for professional mechanics and experienced DIY enthusiasts. Covers everything from basic adjustments to complete engine and gearbox rebuilds. Diagnostic Tools: Information on using basic tools and diagnostic techniques for electrical and mechanical faults. 📊 Manual Specifications File Format PDF Quality: High-resolution scans, clear text and diagrams, searchable content. Print Quality Print Recommendation: Optimized for digital viewing, printable on standard home/office printers. Binding Type Binding: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 90-degree V-twin, two-stroke Displacement: 249 cc Bore X Stroke: 54 x 54.5 mm Compression Ratio: 7.5:1 Power Valve System: APR (Aprilia Performance RoutedEventArgs) - electronically controlled exhaust power valve system. Cylinder Head: Transfer port induction, reed valve intake. Exhaust System: Dual expansion chambers with catalytic converters (in some markets). Performance Horsepower: Approx. 70-74 HP (at crank) Torque: Approx. 45-48 Nm Fuel System Carburetors: 2 x Mikuni TM34SS flat-slide carburetors Fuel Type: Unleaded gasoline (95-98 RON) Oil Injection: Automatic separate lubrication system 🔧 Transmission Standard Type: 6-speed sequential manual Clutch: Wet multi-plate, cable-actuated Features Gear Ratios: Specific ratios provided within the manual. 📐 Dimensions Exterior Length: Approx. 1980 mm Width: Approx. 700 mm Height: Approx. 1135 mm Weights Dry Weight: Approx. 140 kg Seat Height: Approx. 810 mm Wheelbase: Approx. 1370 mm 🛡️ Safety Features Active Features Braking System: Dual front discs with 4-piston calipers, single rear disc with 2-piston caliper. (Specific caliper brands like Brembo may be detailed). Passive Features Frame Type: Aluminum twin-spar frame derived from racing. 💡 Technology Features Infotainment Infotainment System: N/A (Focus on pure performance, no integrated digital systems). 🔧 Maintenance Service Intervals Oil Change Interval: Recommended every 3,000-5,000 km or annually. Spark Plug Replacement: Refer to manual for specific intervals based on usage and plug type (e.g., NGK BR9EG). Chain Lubrication Adjustment: As needed, typically every 500-1000 km. Fluid Specifications Engine Oil Type: High-quality 2-stroke synthetic oil, specific grades (e.g., Motul 800 2T Factory Line) recommended in manual. Coolant Type: Ethylene glycol based antifreeze mixture (50/50 with distilled water). Specific capacity detailed in manual. Brake Fluid Type: DOT 4 hydraulic brake fluid. Transmission Oil Type: Specific gear oil for wet clutches, e.g., SAE 10W-30 or 80W-90 depending on manufacturer recommendation. Known Issues Common Wear Items: Carburetor jets clogging, power valve solenoid failures, crankshaft seals degradation, clutch wear, front fork seals. Tuning Considerations: Sensitivity to carburetor jetting, exhaust system changes, and altitude. Proper setup crucial for optimal performance. 📚 Vehicle History Brand Heritage Heritage: Aprilia's strong racing pedigree, particularly in the 125cc and 250cc Grand Prix classes, heavily influenced the RS250's design and engineering. Model Evolution Development: Developed in collaboration with Suzuki, utilizing their highly successful RG500 Gamma engine architecture (modified for 250cc). Post 1997 Updates: Subsequent models (MK2 onwards) featured updated styling, chassis refinements, and minor engine tweaks. This manual specifically covers the earlier MK1 variants. Production Production Period: 1994-2003 (with MK1 covering 1994-1997). 🏆 Awards & Recognition Recognitions Motorcycle Press Reviews: Consistently...