🏷️ Basic Information Identification Make: Aprilia Model: RS 250 Model Generation: MK1 (External Frame) Codes Vin Decode Prefix: ZDM670 👋 Introduction Market Position Segment: Lightweight Supersport / Sportbike Competitive Analysis Key Competitors: Yamaha YZF-R6, Kawasaki Ninja ZX-6R, Suzuki GSX-R600, Honda CBR600F. Key Features Engine Type: Liquid-cooled, 2-stroke, V-twin (Suzuki RG500 derived engine). Performance Focus: High-revving, agile handling, race-inspired design and performance. Handling Characteristics: Renowned for its sharp steering, stable chassis, and excellent feedback. 📋 Manual Details Coverage Areas Years Covered: 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002 Page Count Estimated Page Count: 300+ Manual Type Type: Factory Service Repair Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Full disassembly, inspection, repair, and reassembly of the Rotax 2-stroke V-twin engine. Engine Management: Carburetor tuning (Dell'Orto PHBH 28/30), ignition system diagnostics, exhaust system analysis. Fuel System: Fuel tank, petcock, fuel lines, oil injection system. Cooling System: Radiator, coolant hoses, water pump, thermostat operation. Transmission: Clutch operation, gear shifting mechanism, gearbox inspection and repair, chain and sprocket maintenance. Brakes: Front and rear brake caliper service, master cylinders, brake lines, brake fluid replacement and bleeding. Suspension: Front telescopic forks (Marzocchi M1, Showa), rear monoshock (Monolever), spring and damping adjustments, fork seal replacement. Electrical System: Wiring diagrams, lighting, battery, charging system, starter motor, ignition coils, instrument cluster. Chassis And Bodywork: Frame inspection, fairing removal and installation, seat, fuel tank, fenders, exhaust silencers. Procedures Included Routine Maintenance: Oil changes, spark plug replacement, air filter cleaning/replacement, chain lubrication and adjustment, brake pad inspection. Troubleshooting: Diagnostic flowcharts for common engine performance issues, electrical faults, and starting problems. Engine Overhaul: Piston and ring replacement, cylinder head service, crankshaft and connecting rod inspection, crank seal replacement. Suspension Rebuild: Front fork internal service, shock absorber service. Electrical Diagnostics: Testing of charging system components, ignition timing verification, common fault finding. Technical Depth Depth: Comprehensive from basic maintenance to complete engine and chassis rebuilds, including detailed specifications and torque values. 📊 Manual Specifications File Format Format: Searchable PDF Print Quality Quality: High-resolution scans of original factory documentation, clear diagrams and text. Binding Type Binding: N/A (Digital Format) Paper Type Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Code: V678 (Rotax 490cc variant) Engine Type: Liquid-cooled, 2-stroke, 90° V-twin Displacement: 249 cc Bore X Stroke: 54 mm x 54.5 mm Compression Ratio: 7.1:1 Peak Horsepower: 70.7 hp (52.7 kW) @ 10,500 rpm Peak Torque: 32.1 lb-ft (43.5 Nm) @ 10,000 rpm Performance Redline: 11,500 rpm Fuel System Carburetors: 2 x Dell'Orto PHBH 28/30 Fuel Delivery: Pre-mix (Manual or Automatic Oil Injection System) Fuel Tank Capacity: 16 Liters (4.2 US gal) 🔧 Transmission Standard Type: 6-speed constant mesh sequential Features Clutch: Wet multi-plate Final Drive: Chain drive 📐 Dimensions Exterior Length: 1985 mm (78.1 in) Width: 730 mm (28.7 in) Height: 1140 mm (44.9 in) Wheelbase: 1370 mm (53.9 in) Seat Height: 810 mm (31.9 in) Weights Dry Weight: 165 kg (364 lbs) Wet Weight: Approx. 185 kg (408 lbs) 🛡️ Safety Features Ratings Crash Test Ratings: N/A (Motorcycle) Active Features Brakes: Dual 320 mm discs front with 4-piston calipers, Single 240 mm disc rear with 2-piston caliper. Passive Features Lighting: Halogen headlight, LED taillight. 💡 Technology Features Infotainment Features: N/A (Basic Analog Instruments) Engine Control Ignition: Digital CDI (Capacitor Discharge Ignition) with electronic power valve control. 🔧 Maintenance Service Intervals Oil Change Recommendation: Every 4,000-6,000 km or annually, using high-quality 2-stroke oil for the injection system. Spark Plug Replacement: Every 6,000-8,000 km (e.g., NGK BR9EG or equivalent). Chain Maintenance: Lubrication and cleaning every 500-1000 km. Adjustment as needed. Major Engine Service: Recommended around 20,000-30,000 km for piston ring and cylinder inspection/replacement. Crank rebuild at higher mileage. Fluid Specifications Engine Oil: High-quality 2-stroke motorcycle oil (synthetic recommended) for injection pump. Pre-mix ratio as per manual if injection is bypassed. Coolant: 50/50 mix of ethylene glycol-based antifreeze and distilled water. Brake Fluid: DOT 4 (or DOT 5.1) brake fluid. Gearbox Oil: API GL-4 or GL-5 SAE 75W/90 synthetic gear oil. Capacity approx. 0.75 Liters. Known Issues Power Valves: Carbon build-up in the exhaust powervalves can lead to poor performance or seizing. Requires regular cleaning. Crank Seals: Leaking crank seals can cause the engine to run lean or suck in gearbox oil, leading to poor running or seizing. Electrical Connections: Corrosion on electrical connectors, especially around the CDI unit and wiring harness, can cause intermittent electrical issues. Clutch Slippage: Can occur with high mileage or aggressive use; requires clutch plate replacement. 📚 Vehicle History Brand Heritage Manufacturer: Aprilia S.p.A., Italy Model Evolution Development Basis: Derived from Aprilia's successful Grand Prix racing machines, particularly the RS250 GP and RGV250 Gamma. Key Updates: MK1 (external frame) and MK2 (internal frame, improved aerodynamics, better suspension) generations. This manual covers the MK1. Production Production Years: 1995-2002 Manufacturing Location: Noale, Italy 🏆...