🏷️ Basic Information Identification Make: Aprilia Model: RS250 Year: 2004 Market Segment: Sportbike / Supersport Motorcycle Generation Generation Identifier: Second Generation (Post-Suzuki Partnership) 👋 Introduction Market Position Segment: Lightweight 2-stroke supersport motorcycle segment Competitors: Yamaha YZF-R6, Suzuki GSX-R600, Kawasaki Ninja ZX-6R, Honda CBR600F/RR (period competitive landscape) Key Features Engine Type: Parallel-twin, liquid-cooled, 2-stroke Performance Focus: High-revving, peaky power delivery characteristic of 2-stroke engines Chassis Design: Lightweight aluminum frame, often featuring premium suspension components like Öhlins Heritage: Direct lineage to the legendary RGV250 GP race bikes 📋 Manual Details Coverage Areas Engine: Comprehensive coverage Transmission: Complete rebuild and adjustment procedures Chassis: Frame, suspension, steering, wheels, tires Electrical System: Wiring diagrams, ignition, lighting, charging system Braking System: Hydraulic systems, caliper service, fluid replacement Cooling System: Radiator, hoses, thermostat, coolant specifications Fuel System: Carburetor tuning, fuel pump, fuel tank service Bodywork: Fairing removal/installation, seat, fuel tank, body panel service Troubleshooting: Diagnostic procedures for common and complex issues Page Count Estimated Pages: 300+ Manual Type Type: Factory Service Repair Manual Scope: Comprehensive repair and maintenance Language Language: English Format Format: Downloadable PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Top-end (cylinders, pistons, cylinder heads), bottom-end (crankshaft, connecting rods, bearings), timing, valve adjustments (where applicable) Engine Management: Ignition system (CDI, spark plugs), fuel delivery (carburetors, jetting), lubrication system Exhaust System: Expansion chambers, mufflers, catalytic converter (if applicable) Clutch: Wet multi-plate clutch operation, adjustment, and replacement Suspension Front: Telescopic forks (Öhlins or Showa depending on variant), damping, spring preload, oil specifications Suspension Rear: Monoshock absorber, linkage system, damping adjustments, spring preload Wheels And Tires: Wheel bearing service, tire mounting, recommended tire pressures Steering System: Steering head bearing service and adjustment Lighting And Signals: Headlight, taillight, turn signals, brake light operation and bulb types Instrumentation: Tachometer, speedometer, warning lights, gauge cluster service Procedures Included Routine Maintenance: Oil changes, filter replacement, chain adjustment, brake checks, spark plug replacement Engine Rebuild: Full disassembly, inspection, measurement, and reassembly procedures Carburetor Service: Disassembly, cleaning, jetting, synchronization, and adjustment Suspension Servicing: Fork seal replacement, fork oil changes, shock absorber servicing Electrical Diagnostics: Troubleshooting shorts, open circuits, and component failures using wiring diagrams Brake System Maintenance: Brake pad replacement, caliper servicing, hydraulic fluid bleeding and replacement Cooling System Flushing: Coolant replacement and system bleeding procedures Bodywork Repair: Fairing removal, installation, and minor repair guidance Technical Depth Depth: Comprehensive, from basic maintenance to full engine and chassis overhauls Diagnostic Capabilities: Detailed fault finding charts and troubleshooting trees Torque Specifications: All critical fasteners specified Dimensional Data: Clearances, tolerances, and wear limits for key components 📊 Manual Specifications File Format Format: PDF Searchability: Text-searchable (OCR quality dependent on original scan) Print Quality Resolution: High resolution, suitable for printing Scalability: Scalable for individual page printing or full manual binding Binding Type Binding: N/A (Digital Download - Print at your discretion) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Configuration: 90-degree V-twin, liquid-cooled, 2-stroke Displacement: 249 cc Bore X Stroke: 54.0 mm x 54.5 mm Compression Ratio: 7.2:1 (approximate) Valve Actuation: Reed valve induction with powervalves (AETC - Aprilia Exhaust Power Valve Control) Performance Horsepower: Approx. 65-70 HP (at crankshaft, depending on market and tuning) Torque: Approx. 40-42 Nm Fuel System Carburetors: Twin 32mm Mikuni TM32SS flat-slide carburetors Fuel Delivery: Gravity feed with electric fuel pump for priming/assistance Oil System: Premix (separate oil tank with automatic injection to fuel) 🔧 Transmission Standard Type: 6-speed constant mesh, sequential manual Features Clutch Type: Wet, multi-plate Final Drive: Chain drive (520 pitch, typically 106 links) 📐 Dimensions Exterior Length: Approx. 1990 mm Width: Approx. 710 mm Height: Approx. 1135 mm Wheelbase: Approx. 1375 mm Weights Dry Weight: Approx. 142 kg Wet Weight: Approx. 156 kg (fully fueled, fluids) Fuel Capacity: 16 liters (including 3.5 liter reserve) 🛡️ Safety Features Ratings Safety Certification: Not applicable for motorcycles in the same way as cars; meets relevant European and international road safety standards for motorcycles. Active Features Brakes Front: Dual 320mm discs, 4-piston calipers (e.g., Brembo or Nissin) Brakes Rear: Single 240mm disc, 2-piston caliper Tires Front: 120/60 ZR17 Tires Rear: 160/60 ZR17 Passive Features Lighting: Halogen headlight, LED taillight Chassis Stiffness: Twin-spar aluminum frame for rigidity and handling 💡 Technology Features Infotainment Infotainment System: N/A (No infotainment system present; purely performance-focused motorcycle) Driver Assistance Traction Control: N/A (No traction control system) ABS: N/A (No Anti-lock Braking System) Connectivity Connectivity Features: N/A (No connectivity features) Engine Management Tech Electronic Control: Aprilia Exhaust Power Valve Control (AETC) system for variable exhaust port timing. 🔧 Maintenance Service Intervals Oil Change: Every 3,000-5,000 km, or annually. Check gearbox oil level regularly. Spark Plug Replacement: Every 5,000-7,000 km (NGK BR9EG recommended) Air Filter Cleaning: Every 3,000 km, clean and re-oil if foam type. Chain Lubrication And Adjustment: Every 500 km, or as needed based on riding conditions. Brake Fluid Flush: Every 2 years or...