🏷️ Basic Information Identification Make: Aprilia Model: RS250 Year: 1999 Generation Generation Designation: MK II Codes Vin Prefix: ZDM63B 👋 Introduction Market Position Segment: Lightweight sportbike, two-stroke performance Target Audience: Enthusiasts, track day riders, mechanics, owners seeking in-depth maintenance knowledge Competitive Analysis Competitors: Yamaha YZF-R6, Suzuki GSX-R600, Kawasaki Ninja ZX-6R, Honda CBR600F/RR Key Features Performance Focus: Renowned for its potent two-stroke engine and sharp handling. Handling Characteristics: Agile and precise, favored by track enthusiasts. Engine Technology: Under-piston induction (2-stroke) with electronically controlled power valves. 📋 Manual Details Coverage Areas General Coverage: All Models, Engines, Trim, Transmission Types Page Count Estimated Page Count: 300+ Manual Type Type: Workshop Repair Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Systems: Engine disassembly and assembly, lubrication system, cooling system, fuel system, ignition system, exhaust system, engine tuning, performance analysis, carburetor tuning (Dell'Orto PHBH 28), reed valve operation, power valve operation. Transmission Drivetrain: Clutch system, gearbox operation, gear selection, final drive, chain maintenance, lubrication. Chassis Suspension: Frame, front forks (Showa 43mm USD), rear shock absorber (Monoshock), swingarm, steering head bearings, wheel bearings, suspension tuning, sag adjustment. Braking System: Front brakes (dual hydraulic disc, Brembo 4-piston calipers), rear brake (hydraulic disc, Brembo caliper), brake fluid specifications, bleeding procedures, pad replacement, caliper overhaul. Electrical System: Ignition system (CDI), lighting system (headlight, taillight, indicators), battery, charging system (alternator, regulator/rectifier), starter motor, wiring diagrams, troubleshooting electrical faults. Bodywork Fairings: Fairing removal and installation, seat, fuel tank, fender replacement, cosmetic repairs. Procedures Included Maintenance: Routine checks, oil changes, filter replacements, spark plug replacement, chain adjustment, lubrication points, brake fluid flush, coolant flush, carburetor cleaning and synchronization. Troubleshooting: Diagnosis of common running issues, electrical faults, starting problems, cooling system leaks, brake system malfunctions, exhaust system performance issues. Repair: Engine rebuilds, transmission overhaul, suspension component replacement, brake caliper rebuilding, electrical component repair, fairing repair. Diagnostics: Engine performance diagnostics, electrical system diagnostics using wiring diagrams, identifying common failure points. Technical Depth Depth: Comprehensive. Covers basic maintenance to full engine and chassis rebuilds. Includes detailed exploded views, torque specifications, and diagnostic flowcharts. 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text Print Quality Quality: High-resolution scans ensuring clarity of diagrams and text Binding Type Binding: Not Applicable (Digital Download) Paper Type Paper Type: Not Applicable (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 2-stroke, V-twin (90-degree) Displacement: 249 cc Bore X Stroke: 54 mm x 54.5 mm Compression Ratio: 7.1:1 Power Valves: Electronic control system for power band optimization. Performance Horsepower: 70.7 hp (52.7 kW) @ 11,000 rpm (approximate, manufacturer claimed) Torque: 30.7 ft-lbs (41.6 Nm) @ 10,500 rpm (approximate, manufacturer claimed) Fuel System Carburetion: 2 x Dell'Orto PHBH 28 carburetor Fuel Delivery: Petcock operated, gravity feed with oil injection system Lubrication Oil Type: Specific 2-stroke motorcycle oil (e.g., Motul 800 2T, Castrol TTS). Refer to manual for precise API TC or ISO-L-EGD classification. Cooling System Coolant Type: Ethylene glycol-based coolant with anti-corrosion additives. Mix 50/50 with distilled water. 🔧 Transmission Standard Transmission Type: 6-speed, constant mesh Features Clutch Type: Wet, multi-plate Final Drive: Chain drive Gear Ratios: Refer to manual for specific gear ratios (e.g., 1st: 2.333, 2nd: 1.765, 3rd: 1.400, 4th: 1.182, 5th: 1.045, 6th: 0.958) Transmission Oil: API GL-4 or GL-5, SAE 75W-90 or 80W-90 gear oil. Capacity: approx. 0.75 Liters. 📐 Dimensions Exterior Length: Approx. 1970 mm Width: Approx. 710 mm Height: Approx. 1145 mm Wheelbase: Approx. 1365 mm Weights Dry Weight: Approx. 141 kg Wet Weight: Approx. 156 kg (fully fueled) Fuel Capacity: 16 Liters Oil Tank Capacity: 1.5 Liters Wheels Tires Front Tire Size: 120/70-17 Rear Tire Size: 160/60-17 Wheel Bolt Pattern: N/A (Cast alloy wheels) Front Wheel Type: Cast alloy Rear Wheel Type: Cast alloy 🛡️ Safety Features Ratings Safety Ratings: N/A (Motorcycle, not subject to automotive crash testing standards) Active Features Braking System: Dual front Brembo 4-piston calipers with 320mm discs, single rear Brembo caliper with 240mm disc. Highly effective. Suspension Stability: Sport-tuned Showa front forks and monoshock rear suspension for precise control. Passive Features Frame Construction: Aluminum alloy twin-spar frame for rigidity and light weight. Lighting: Halogen headlight, LED taillight and turn signals (depending on market specification). 💡 Technology Features Infotainment Infotainment System: N/A (No integrated infotainment system, basic analog instrumentation). Driver Assistance Driver Assistance: N/A (No electronic driver assistance features). Instrumentation Instrument Cluster: Analog speedometer, tachometer, coolant temperature gauge, neutral indicator, turn signal indicators, high beam indicator. Engine Management Engine Control Unit: CDI ignition with electronic power valve control (APEC system). 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,000-4,000 km or annually. Check 2-stroke oil level frequently. Spark Plug Replacement: Every 6,000-8,000 km (e.g., NGK BR9EG or equivalent). Chain Lubrication Adjustment: Every 500-800 km, adjust tension as needed. Brake Fluid Flush: Every 2 years, or as per manual recommendation. Use DOT 4...