🏷️ Basic Information Identification Make: Aprilia Model: RS250 Year: 1996 Market: Global (primarily European and North American markets) Codes Chassis Code Prefix: AP01 👋 Introduction Market Position Positioning: The Aprilia RS250 was a highly regarded, performance-oriented supersport motorcycle, aimed at enthusiasts seeking track-day capability and exhilarating two-stroke performance. It competed with other 250cc two-stroke sportbikes of its era. Competitive Analysis Key Competitors: Yamaha YZF-R250, Honda NSR250R, Suzuki RGV250 Gamma. Key Features Distinguishing Features: Powerful two-stroke V-twin engine, aggressive styling, excellent handling, derived from race-winning technology. Value Proposition Manual Value: This manual is essential for owners and technicians to maintain, diagnose, and repair the iconic Aprilia RS250, preserving its performance and longevity. It provides the critical technical data needed to work on this complex machine. 📋 Manual Details Coverage Areas Coverage Scope: All Models, Engines, Trims, Transmissions (referring to the single RS250 variant of 1996) Page Count Estimated Pages: 300-400 Manual Type Type: Workshop Repair Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Detailed breakdown of the 249cc liquid-cooled V-twin two-stroke engine, including Suzuki RGV250 derived components. Cooling System: Radiator, coolant flow, pump, thermostat, and troubleshooting for overheating. Fuel System: Carburetor (likely Mikuni TM32SS) adjustment, cleaning, and rebuilding, fuel pump, fuel lines, and tank maintenance. Ignition System: CDI ignition, spark plugs, ignition timing, stator, and troubleshooting ignition failures. Transmission: 6-speed gearbox, clutch operation, lubrication, and internal component inspection. Chassis: Frame inspection, alignment, and repair procedures. Suspension Front: 41mm upside-down forks (likely Showa), oil levels, seal replacement, damping adjustments. Suspension Rear: Monoshock suspension, linkage system, shock absorber adjustment, and rebuild. Brakes Front: Dual 290mm discs, 4-piston calipers (likely Nissin), master cylinder, fluid, and bleeding procedures. Brakes Rear: Single 240mm disc, 2-piston caliper, master cylinder, fluid, and bleeding procedures. Wheels Tires: Wheel bearing maintenance, tire pressure, and sizing. Electrical System: Wiring diagrams, battery, charging system, lights, indicators, and switches. Exhaust System: Expansion chambers, mufflers, and related components. Bodywork: Fairing removal and installation, seat, tank, and minor body panel repairs. Procedures Included Routine Maintenance: Oil changes, filter replacements, chain adjustment, spark plug checks, air filter cleaning. Major Servicing: Engine top-end rebuilds, carburetor synchronisation and tuning, valve clearance (if applicable to two-stroke), suspension servicing. Troubleshooting: Diagnostic guides for common and uncommon issues, fault finding trees for ignition, fuel, and electrical problems. Repair: Step-by-step instructions for component removal, installation, and repair for all major systems. Torque Specifications: Detailed torque settings for critical fasteners throughout the motorcycle. Wiring Diagrams: Complete and detailed electrical schematics for easy fault diagnosis. Technical Depth Depth: Comprehensive, from basic rider maintenance to advanced engine and electrical diagnostics and rebuilds. Diagnostic Tools: Information on required tools and specialized equipment for specific procedures. 📊 Manual Specifications File Format Digital Format: PDF (Portable Document Format) Print Quality Digital Quality: High resolution, suitable for digital viewing and printing. Binding Type Binding: N/A (Digital PDF) Paper Type Paper: N/A (Digital PDF) Searchability Text Search: Likely text-searchable PDF for efficient information retrieval. ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 90-degree V-twin, two-stroke Displacement: 249.3 cc (15.22 cu in) Bore X Stroke: 54.0 mm x 54.5 mm (2.13 in x 2.15 in) Compression Ratio: 7.1:1 Power Output Hp: Approx. 70.3 hp (52.4 kW) @ 11,700 rpm (at crankshaft, often derated for road use) Torque: Approx. 45.2 Nm (33.3 lb-ft) @ 10,500 rpm Lubrication: Separate oil injection system for premixing fuel and oil. Performance Top Speed: Approx. 130+ mph (210+ km/h) Fuel System Carburetors: 2 x Mikuni TM32SS, flat slide, with T.C.C.S. (Suzuki's Throttle Control System - variable exhaust powervalves) Fuel Type: Unleaded gasoline, minimum 95 RON (octane rating) Fuel Capacity: 16 Liters (4.2 US gallons) 🔧 Transmission Standard Transmission Type: Constant mesh 6-speed sequential Clutch Type: Wet, multi-plate, cable-actuated Features Gear Ratios: 1st: 2.833 (34/12), 2nd: 2.063 (33/16), 3rd: 1.588 (33/21), 4th: 1.333 (32/24), 5th: 1.150 (23/20), 6th: 1.042 (25/24) Final Drive: Chain drive, 520 O-ring chain Transmission Oil Type: SAE 10W-40 API SG or higher Transmission Oil Capacity: 1.5 Liters (1.6 US quarts) 📐 Dimensions Exterior Length: Approx. 1980 mm (78.0 in) Width: Approx. 710 mm (28.0 in) Height: Approx. 1065 mm (41.9 in) Wheelbase: Approx. 1365 mm (53.7 in) Ground Clearance: Approx. 120 mm (4.7 in) Weights Dry Weight: Approx. 140 kg (308.6 lbs) Wet Weight: Approx. 166 kg (366.0 lbs) Max Load: Approx. 180 kg (397 lbs) including rider and luggage 🛡️ Safety Features Ratings Safety Standards: Designed to meet relevant European and US road safety standards for motorcycles of its era. Active Features Braking System: Powerful dual-disc front and single-disc rear braking system provides strong stopping power. Handling Dynamics: Performance-oriented chassis and suspension contribute to predictable and stable handling. Passive Features Lighting: Halogen headlamp and tail light for visibility. 💡 Technology Features Infotainment Infotainment System: N/A (Not applicable to this model; focus is on pure performance). Driver...