🏷️ Basic Information Identification Make: Aprilia Model: RS250 Generation Generation Code: MK I / MK II Production Years: 1998-2004 Codes Chassis Code Early: AP81100 Chassis Code Late: AP81101 (MK II) 👋 Introduction Market Position Market Segment: High-performance, track-focused sportbike in the 250cc class, known for its handling and potent 2-stroke engine. Competitive Analysis Key Competitors: Yamaha YZF-R25, Suzuki RG500 Gamma (older but similar class), Honda NSR250R (direct competitor). Key Features Engine Type: Liquid-cooled, 2-stroke, 90-degree V-twin, derived from Suzuki RG-V XR89 race bike. Performance Reputation: Renowned for its sharp handling, powerful mid-range, and track capability. Chassis Design: Lightweight aluminum twin-spar frame and advanced suspension components contributing to exceptional agility. Dual Exhaust: Distinctive dual under-seat exhaust system. 📋 Manual Details Coverage Areas Coverage Years: 1998, 1999, 2000, 2001, 2002, 2003, 2004 Page Count Estimated Page Count: 300-400 pages (estimated based on typical workshop manuals) Manual Type Type: Workshop Repair Service Manual Language Language: English (primary language indicated by description) Format Format: PDF 📖 Manual Coverage Systems Covered Engine: Comprehensive coverage of the 2-stroke V-twin engine, including top-end and bottom-end rebuilds, lubrication, cooling, and exhaust systems. Fuel System: Detailed information on the carburetor system (Mikuni TMR32), fuel pump, fuel lines, and fuel tank maintenance and troubleshooting. Ignition System: Coverage of the electronic ignition system, CDI unit, spark plugs, and associated wiring. Transmission: Complete instructions for clutch operation, gearbox disassembly and reassembly, shift mechanism, and maintenance of transmission fluids. Chassis Frame: Information regarding the aluminum twin-spar frame, sub-frame, and any related structural components. Suspension Front: Detailed procedures for servicing and rebuilding the upside-down (USD) front forks, including oil changes, seal replacement, and damping adjustments. Suspension Rear: Comprehensive guide to the monoshock rear suspension system, including shock absorber maintenance, linkage lubrication, and adjustments. Brakes Front: In-depth coverage of the dual front disc brake system, including caliper overhaul, master cylinder maintenance, brake pad replacement, and bleeding procedures. Brakes Rear: Information on the rear disc brake system, including caliper maintenance, brake pad replacement, and bleeding. Wheels Tires: Guidelines for wheel bearing maintenance, tire replacement, and recommended tire pressures. Electrical System: Extensive coverage of the electrical system, including wiring diagrams, lighting, battery maintenance, charging system, and component testing. Cooling System: Details on the liquid cooling system, including radiator, water pump, thermostat, coolant type, and fluid change procedures. Exhaust System: Information on the dual exhaust system, including pipe maintenance and gasket replacement. Bodywork Fairings: Procedures for removing and installing body panels, fairings, and related trim components. Procedures Included Routine Maintenance: Covers all routine checks, adjustments, and replacements such as oil changes, filter replacements, chain adjustments, and spark plug replacements. Engine Overhaul: Step-by-step instructions for engine disassembly, inspection, component replacement (pistons, rings, bearings), and reassembly. Carburetor Tuning: Detailed guidance on carburetor synchronization, jetting, and adjustment for optimal performance. Suspension Servicing: Complete procedures for fork seal replacement, fork oil viscosity and level checks, and rear shock absorber adjustments. Brake System Overhaul: Instructions for caliper rebuilding, master cylinder replacement, and complete brake system bleeding. Electrical Troubleshooting: Systematic approach to diagnosing and resolving electrical issues, including fault finding and component testing. Clutch Adjustment Replacement: Procedures for clutch lever free play adjustment and clutch pack replacement. Gearbox Rebuild: Detailed steps for disassembling and reassembling the transmission, including inspection of gears, shafts, and bearings. Wheel Bearing Replacement: Instructions for replacing front and rear wheel bearings. Coolant Flush And Refill: Guidance on draining, flushing, and refilling the cooling system with the correct coolant type. Tire Mounting Balancing: Basic instructions for tire removal, installation, and balancing. Chassis Component Replacement: Procedures for replacing steering components, swingarm bearings, and other chassis parts. Technical Depth Diagnostic Capabilities: Advanced diagnostic procedures for identifying and rectifying common and uncommon faults, supported by troubleshooting flowcharts. Rebuild Procedures: Comprehensive rebuild procedures for major mechanical components including the engine, gearbox, forks, and brake calipers. Technical Specifications: Includes detailed technical data, torque values, clearances, fluid capacities, and electrical specifications. Wiring Diagrams: Detailed and clear wiring diagrams for the entire motorcycle, crucial for electrical troubleshooting. Part Breakdowns: Likely includes exploded views of various assemblies, aiding in identification and correct reassembly of parts. 📊 Manual Specifications File Format PDF Quality: High-resolution PDF, optimized for readability and printing. Likely searchable text. Print Quality Printability: Designed to be printable, allowing users to create physical copies for workshop use. Binding Type Binding: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 2-stroke, V-twin Displacement: 249 cc Bore X Stroke: 54.0 mm x 54.5 mm Compression Ratio: 7.1:1 (approx.) Valvetrain: Reed valve induction, Suzuki Powervalve (SAEC - Suzuki Advanced Engine Control) exhaust powervalves. Performance Horsepower: Approximately 70-73 hp (at crankshaft) depending on region and tuning. Torque: Approximately 38-40 Nm (at crankshaft) depending on region and tuning. Fuel System Carburetors: 2 x Mikuni TMR32 flat-slide carburetors Fuel Capacity: 16 Liters (4.2 US gallons)...