🏷️ Basic Information Identification Make: Aprilia Model: RS 250 Year: 1996 Codes Engine Code: Rotax 257 👋 Introduction Market Position Description: The Aprilia RS 250 was a highly regarded sportbike of its era, known for its lightweight chassis, powerful two-stroke engine derived from Suzuki's RGV250, and track-inspired performance. It competed against other 250cc two-stroke sportbikes from Japanese manufacturers. Competitive Analysis Competitors: Suzuki RGV250, Yamaha TZR250, Kawasaki KR-1S. Key Features Performance Focus: The manual reflects the performance-oriented nature of the RS 250, providing detailed information for enthusiasts and mechanics to maintain and optimize its capabilities. 📋 Manual Details Coverage Areas Primary Coverage: Comprehensive repair and service procedures for the Aprilia RS 250 (1996 model year). Secondary Coverage: General information, periodic maintenance, tune-up procedures, engine, fuel and lubrication systems, cooling system, electrical system, chassis, servicing information, and updates. Page Count Estimated Page Count: Likely over 300 pages, typical for a factory-level service manual. Manual Type Type: Factory Service Repair Manual Language Language: English (assumed based on common availability, but verification recommended). Format Format: PDF 📖 Manual Coverage Systems Covered Engine Systems: Engine assembly, disassembly, cylinder head, piston, crankshaft, connecting rod, lubrication system, cooling system (radiator, water pump, thermostat). Fuel Lubrication Systems: Carburetor system (Mikuni TM34SS), fuel delivery, oil injection system, fuel tank, fuel lines. Electrical System: Ignition system (CDI), lighting system, battery, charging system (alternator), starter motor, wiring diagrams, fault diagnosis. Chassis Systems: Frame, front suspension (telescopic forks, spring preload, damping adjustments), rear suspension (monoshock, linkage), steering system, wheels, braking system (front and rear disc brakes, master cylinders, calipers), exhaust system. Procedures Included Maintenance Procedures: Oil change, spark plug replacement, air filter cleaning/replacement, chain adjustment, brake fluid replacement, coolant flush, carburetor synchronization, periodic inspections. Tune Up Procedures: Engine timing adjustments, carburetor jetting, idle speed setting, compression testing. Repair Procedures: Engine rebuilds, transmission service, suspension overhaul, brake caliper rebuilds, electrical component diagnosis and replacement. Troubleshooting Guidance: Step-by-step diagnostic trees and symptom-based problem solving for common issues. Technical Depth Depth: Comprehensive, covering all aspects of workshop procedures from basic maintenance to full engine and chassis rebuilds, including detailed diagrams and torque specifications. 📊 Manual Specifications File Format Compatibility: Compatible with all versions of Windows and Mac. Requirements: Adobe PDF Reader and WinZip. Features: Zoom in/out functionality for detailed viewing. Print Quality Printability: Designed to be printable for physical reference. Binding Type Binding: N/A (Digital PDF format) Paper Type Paper Type: N/A (Digital PDF format) ⚙️ Engine Specifications Primary Engine Type: Liquid-cooled, 2-stroke, V-twin (90-degree) Displacement: 249 cc Bore X Stroke: 54 mm x 54.5 mm Power Output: Approximately 70 hp (at crankshaft) in unrestricted European/Japanese spec, ~65 hp in US spec. Torque: Approximately 39 Nm (28.7 lb-ft) at 9,000 rpm. Performance Ignition: Digital CDI with separate oil injection. Fuel System Carburetors: Dual Mikuni TM34SS constant velocity carburetors. Fuel Type: Unleaded premium gasoline (95-98 RON). Cooling System Type: Liquid-cooled. Lubrication System: Premix or Automatic Oil Injection (separate oil tank). 🔧 Transmission Standard Type: 6-speed constant mesh, sequential manual. Clutch: Wet, multi-plate, cable-actuated. Features Gear Ratios: Specific ratios covered in detail within the manual. Final Drive: Chain drive. 📐 Dimensions Exterior Length: Approx. 1995 mm (78.5 in) Width: Approx. 710 mm (28.0 in) Height: Approx. 1135 mm (44.7 in) Weights Dry Weight: Approx. 142 kg (313 lbs) Wet Weight: Approx. 153 kg (337 lbs) (with all fluids) Fuel Capacity: 16 liters (4.2 US gallons) Oil Capacity: Approx. 0.7 liters (for automatic injection system) 🛡️ Safety Features Ratings Notes: Motorcycles of this era did not have standardized safety rating systems comparable to modern cars. Safety features are inherent to the design and rider input. Active Features Braking System: Dual front discs (320mm) with twin-piston calipers, single rear disc (240mm) with twin-piston caliper. The manual details maintenance and bleeding procedures for this hydraulic system. Suspension: Adjustable front forks and rear monoshock contribute to stability and rider control. Passive Features Frame Design: Lightweight twin-spar aluminum frame provides structural integrity. 💡 Technology Features Infotainment System: N/A (This is a 1996 sportbike, no infotainment systems.) Driver Assistance System: N/A (No electronic driver assistance features beyond basic ABS on later models or specific aftermarket additions.) 🔧 Maintenance Service Intervals Oil Change: Recommended every 5,000 km or annually. (Specific interval detailed in manual). Spark Plugs: Recommended inspection/replacement every 10,000 km. (Specific type and gap in manual). Chain Maintenance: Lubrication and adjustment recommended every 1,000 km or after riding in wet conditions. Coolant Replacement: Recommended every 2 years. (Specific coolant type in manual). Fluid Specifications Engine Oil: For the automatic injection system, use a high-quality 2-stroke synthetic injection oil. (Specific Aprilia or API/JASO standard in manual). Transmission Oil: Hypoid gear oil SAE 80W-90 API GL-4. (Specific capacity in manual). Brake Fluid: DOT 4 or DOT 5.1. (Manual will specify preferred type and bleeding procedure). Coolant: Ethylene glycol-based coolant with anti-corrosion additives, mixed 50/50 with...