🏷️ Basic Information Identification Make: Aprilia Model: RS250 Product Name: Aprilia RS250 1994-2008 Service Repair Manual Codes Model Code Range: APRNRS250-1994-2008 👋 Introduction Market Position Segment: Lightweight Two-Stroke Sportbike Competitive Analysis Key Competitors: Yamaha YZF-R6, Suzuki GSX-R600, Kawasaki Ninja ZX-6R (early models), Honda CBR600F Key Features Engine Type: High-performance V-twin, two-stroke, liquid-cooled Handling: Renowned for its sharp handling and agility, derived from GP racing technology Design: Aggressive, race-inspired styling and aerodynamic bodywork 📋 Manual Details Coverage Areas Years Covered: 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008 Manual Type Type: Service and Repair Manual Language Language: English Format Format: Digital (likely PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Top-end, bottom-end, cooling system, lubrication, fuel injection, exhaust system Electrical System: Ignition, charging system, lighting, starter motor, wiring diagrams, ECU diagnostics Chassis And Suspension: Front fork, rear shock absorber, swingarm, frame, steering system Braking System: Front and rear calipers, master cylinders, brake lines, disc maintenance, bleeding procedures Fuel System: Carburetors (Mikuni TMR flat slide), fuel tank, fuel pump, fuel lines Transmission And Drivetrain: Gearbox, clutch, chain drive, gear ratios, lubrication Bodywork And Trim: Fairings, seat, handlebars, footpegs, body panel removal and installation Procedures Included Maintenance: Oil changes, filter replacements, chain adjustment, spark plug service, brake fluid flush Troubleshooting: Diagnostic charts for common performance issues, starting problems, electrical faults Repair: Engine rebuilds, carburetor tuning, suspension overhaul, brake system repairs, electrical component replacement Disassembly And Assembly: Step-by-step instructions for major component removal and reinstallation Technical Depth Depth: Comprehensive coverage from basic maintenance to complete engine and chassis overhauls 📊 Manual Specifications File Format Format Details: Searchable PDF with high-resolution images and diagrams Print Quality Print Readability: Designed for clear print reproduction, including detailed diagrams Binding Type Binding: N/A (Digital Format) Paper Type Paper: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Configuration: 70° V-twin, two-stroke, reed valve induction Displacement: 249 cc Bore X Stroke: 54 x 54.5 mm Compression Ratio: 7.5:1 (approximate, varies slightly by year/region) Performance Horsepower: Approx. 65-70 HP @ 11,000 RPM (claimed) Torque: Approx. 30-32 lb-ft @ 10,000 RPM (claimed) Fuel System Carburetors: Twin Mikuni TMR32 flat slide carburetors Ignition System: Digital CDI with dual spark plugs per cylinder Cooling System Type: Liquid-cooled Lubrication Type: Premix or Automatic Oil Injection (Suzuki RGV250 derived system) Exhaust System Configuration: Dual expansion chambers 🔧 Transmission Standard Type: 6-speed sequential, constant mesh Features Clutch Type: Wet multi-plate Final Drive: O-ring sealed chain 📐 Dimensions Exterior Length: Approx. 77.8 in (1975 mm) Width: Approx. 27.6 in (700 mm) Height: Approx. 43.7 in (1110 mm) Weights Dry Weight: Approx. 304 lbs (138 kg) Wet Weight: Approx. 340 lbs (154 kg) Wheelbase Wheelbase: Approx. 54.7 in (1390 mm) Fuel Capacity Fuel Tank Capacity: Approx. 4.5 US gal (17 L) 🛡️ Safety Features Ratings Safety Standards: Motorcycle safety standards applicable to its production era Active Features Braking: Dual front disc brakes, single rear disc brake with 4-piston calipers (later models may have improved caliper design) Suspension: Adjustable front forks (preload, compression, rebound), adjustable rear monoshock Passive Features Frame: Aluminum twin-spar frame providing rigidity and stability 💡 Technology Features Infotainment Features: N/A (Focused on performance and handling, not modern infotainment) Driver Assistance Features: N/A (No electronic rider aids) 🔧 Maintenance Service Intervals Engine Oil Change: Every 2,000-3,000 miles (3,000-5,000 km) or annually, check manual for specifics Spark Plug Replacement: Every 6,000-8,000 miles (10,000-12,000 km) Chain Lubrication: Every 300-500 miles (500-800 km) and after washing/rain Brake Fluid Flush: Every 2 years Fluid Specifications Engine Oil Type: 2-stroke synthetic blend oil suitable for racing applications (e.g., Motul 800 2T Factory Line) Coolant: Ethylene glycol-based coolant with corrosion inhibitors, 50/50 mix with distilled water Brake Fluid: DOT 4 (or specified in manual) Gearbox Oil: API GL-4, SAE 75W-90 or 80W-90 (check manual for specific capacity) Known Issues Engine Wear: High-performance two-strokes require diligent maintenance; piston and cylinder wear can occur if not properly maintained or if used excessively at low RPM. Carburetor Issues: Mikuni TMR carbs can require periodic cleaning and tuning to maintain optimal performance. Electrical Connections: Corrosion or loose connections can lead to intermittent electrical issues. Power Valve System: Rave (Rotary-Activated Valve Exhaust) system can accumulate carbon and require cleaning for optimal performance. 📚 Vehicle History Brand Heritage Brand Origin: Italian manufacturer with a strong racing pedigree, particularly in Grand Prix motorcycle racing Model Evolution Origins: Based heavily on the Suzuki RGV250 Gamma, utilizing its engine and chassis architecture, refined and styled by Aprilia Key Changes: Early models featured slightly different carburetion and styling. Later models saw minor updates to suspension and braking components. Discontinuation due to tightening emissions regulations for two-stroke engines. Production Production Period: 1994 - 2008 (approximately) Manufacturing Location: Italy 🏆 Awards & Recognition Recognitions Industry Awards: Consistently praised by motorcycle journalists for its handling, performance, and unique character...