🏷️ Basic Information Identification Make: Aprilia Model: RS250 Year: 1996 Model Code: RS250 Chassis Code: AP81140 Engine Code Prefix: AP06 👋 Introduction Market Position Category: Sportbike, Supersport Target Audience: Enthusiast owners, independent repair shops, professional mechanics Competitive Analysis Key Competitors 1996: Yamaha YZF600R, Kawasaki Ninja ZX-6, Suzuki GSX-R600 Key Features Unique Selling Proposition: High-performance 2-stroke V-twin engine derived from Suzuki RGV250, aggressive styling, race-bred chassis. Performance Focus: Lightweight, agile, and powerful for its class. 📋 Manual Details Coverage Areas Primary Coverage: Mechanical repair, maintenance, electrical systems, troubleshooting Secondary Coverage: Chassis adjustments, suspension tuning, bodywork Page Count Estimated Page Count: 250+ Manual Type Type: Factory Repair Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: 2-stroke, V-twin cylinder, liquid-cooled, reed valve induction Fuel System: Carburetor identification (Mikuni TMR32), fuel pump operation, fuel tank, fuel lines Ignition System: CDI, spark plug specifications, timing adjustments Lubrication System: Premixing, automatic oil injection system diagnosis and repair Cooling System: Radiator, water pump, thermostat, coolant specifications Transmission: 6-speed constant mesh, clutch operation (wet multi-plate), gearbox disassembly and assembly Frame And Suspension: Aluminum twin-spar frame, front fork (showa upside-down) adjustments and overhaul, rear shock absorber (monoshock) adjustments and overhaul, linkage geometry Brakes: Front: Dual 320mm discs with 4-piston calipers ( Nissin); Rear: Single 240mm disc with 2-piston caliper (Nissin) Electrical System: Wiring diagrams, battery, charging system, lighting, starter motor, instrument panel Exhaust System: Expansion chambers, silencer specifications Procedures Included Maintenance: Oil changes, filter replacements, chain adjustment, spark plug checks, general inspection Engine Rebuild: Top-end overhaul, piston and ring replacement, cylinder boring, crankshaft service Transmission Repair: Gearbox disassembly, component inspection, clutch plate replacement Suspension Tuning: Preload, compression, and rebound damping adjustments for front and rear Carburetor Tuning: Jetting, idle speed, mixture adjustments Electrical Troubleshooting: Diagnostic procedures for common electrical faults, component testing Brake System Maintenance: Pad replacement, fluid bleeding, caliper servicing Wheel And Tire Service: Tire replacement, wheel balancing Technical Depth Depth Level: Comprehensive (from basic maintenance to complete engine rebuild and chassis overhauls) Diagnostic Capability: Includes troubleshooting charts, fault codes (where applicable), and component testing procedures Rebuild Instructions: Detailed step-by-step instructions with torque specifications for major components 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text content Print Quality Printability: Printable pages Binding Type Binding: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: 2-stroke, V-twin, liquid-cooled Displacement: 249 cc Bore X Stroke: 54.0 mm x 54.5 mm Compression Ratio: 7.1:1 Reed Valve System: Suzuki ATAC (Automatic Tractive Efficiency Control) system Performance Horsepower Peak: 70 HP (51 kW) @ 11,000 rpm Torque Peak: 39 Nm (28.8 lb-ft) @ 10,500 rpm Fuel System Carburetors: 2 x Mikuni TMR32 flat slide Fuel Type: Unleaded gasoline (95 RON or higher recommended) Fuel Delivery: Oil Injection System (Premix mandatory if removed/faulty) Lubrication Type Engine Oil Type: 2-stroke, high-performance synthetic oil 🔧 Transmission Standard Transmission Type: 6-speed constant mesh Clutch Type: Wet multi-plate Features Gear Ratios: 1st: 2.500, 2nd: 1.750, 3rd: 1.333, 4th: 1.130, 5th: 0.960, 6th: 0.833 Final Drive: Chain driven Transmission Oil Type: API GL-4, SAE 80W/90 hypoid gear oil Transmission Oil Capacity: Approximately 0.8 Liters 📐 Dimensions Exterior Length: 1990 mm (78.3 in) Width: 720 mm (28.3 in) Height: 1135 mm (44.7 in) Wheelbase: 1375 mm (54.1 in) Weights Dry Weight: 143 kg (315 lbs) Wet Weight: 160 kg (353 lbs) (approx) Fuel Tank Capacity: 16 Liters (4.2 US gal) Seat Height: 810 mm (31.9 in) 🛡️ Safety Features Ratings Safety Ratings: N/A (Motorcycle, specific ratings vary by region/testing) Active Features Braking System: Powerful dual front discs and rear single disc with hydraulic actuation Passive Features Frame Construction: Rigid aluminum twin-spar frame for stability Tires: Sport-oriented radial tires (e.g., 120/60ZR17 front, 160/60ZR17 rear) 💡 Technology Features Infotainment Instrument Cluster: Analog tachometer, speedometer, coolant temperature gauge, odometer, trip meter, indicator lights. Driver Assistance Power Delivery Control: Aprilia's ATAC system for optimized power band and emissions. 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,000 km (1,800 miles) or annually Spark Plug Replacement: Every 6,000 km (3,600 miles) Chain Lubrication Adjustment: Every 1,000 km (600 miles) or after washing/rain Air Filter Cleaning: Every 6,000 km (3,600 miles) Coolant Replacement: Every 2 years Fluid Specifications Coolant Type: Ethylene glycol-based antifreeze (50% solution) - refer to manual for specific Aprilia recommendation Brake Fluid Type: DOT 4 Known Issues Common Problems: Carburetor synchronization, reed valve wear, electrical connector corrosion, exhaust pipe sealing issues, power valve sticking. Maintenance Importance: Crucial for 2-stroke performance; proper premixing, clean carbs, and functioning power valves are key. 📚 Vehicle History Brand Heritage Manufacturer: Aprilia (Italy) Heritage Focus: Renowned for racing success, particularly in Grand Prix with 2-stroke technology. Model Evolution Engine Origin: Based on the acclaimed Suzuki RGV250 Gamma engine (RGV250 'M' or 'V' variants). Development: Aprilia adapted the Suzuki V-twin platform, refining...