🏷️ Basic Information Identification Make: Aprilia Model: RS250 Year Range: 1994-1998 Product Type: Workshop Service Repair Manual 👋 Introduction Market Position Segment: Sportbike / Supersport Era: Mid-1990s performance motorcycle Competitive Analysis Competitors: Yamaha RZ350, Suzuki RGV250, Honda NSR250, Kawasaki KR-1S Key Features Engine Configuration: Lightweight, high-revving 2-stroke V-twin engine known for its exceptional power-to-weight ratio. Design Inspiration: Based on Suzuki RGV250 Gamma donor parts and technology, with Aprilia's chassis and styling refinements. Value Proposition Cost Saving: Inexpensive way to maintain and repair the Aprilia RS250, avoiding dealership service costs. 📋 Manual Details Coverage Areas Covered Years: 1994, 1995, 1996, 1997, 1998 Page Count Estimated Pages: Estimated 300-500 pages (typical for comprehensive service manuals of this era) Manual Type Type: Comprehensive Service and Repair Manual Language Language: English (Standard for most international market manuals) Format Format: Digital (PDF) - Typically provided as a downloadable file 📖 Manual Coverage Systems Covered Engine: Detailed breakdown of the 2-stroke V-twin engine, including top-end and bottom-end assembly, lubrication, cooling, and ignition systems. Fuel System: Carburetor tuning and overhaul (likely Mikuni TM34), fuel delivery, fuel tank, fuel lines. Transmission: Clutch operation and adjustment, gearbox disassembly and reassembly, shift mechanism, lubrication. Chassis: Frame inspection and repair, swingarm, rear suspension (monoshock), linkage system, steering head bearings. Front Suspension: Upside-down telescopic fork (likely Showa) maintenance, fluid changes, seal replacement, and adjustment. Brakes: Front and rear brake system service, caliper overhaul, master cylinder maintenance, fluid bleeding, pad replacement, disc inspection. Electrical System: Wiring diagrams, battery maintenance, lighting system, ignition system troubleshooting, stator and rotor testing, CDI unit. Cooling System: Radiator service, fan operation, coolant type and capacity, thermostat. Exhaust System: Pipe and silencer maintenance, gasket replacement, power valve system operation and cleaning. Bodywork: Fairing removal and installation, seat, fuel tank, fenders. Procedures Included Routine Maintenance: Oil changes, filter replacements, chain adjustment and lubrication, spark plug replacement, air filter cleaning. Troubleshooting: Diagnostic charts for common starting, running, and electrical issues, based on symptoms. Major Repairs: Engine rebuild procedures, transmission overhaul, suspension component replacement, brake system rebuilding. Component Overhaul: Detailed steps for disassembling, cleaning, inspecting, and reassembling key components like carburetors, forks, and brake calipers. Wiring Diagrams: Complete electrical schematics for all systems. Technical Depth Depth: Comprehensive: Covers everything from basic maintenance to full engine teardowns and rebuilds, including detailed specifications for torquing, clearances, and adjustments. 📊 Manual Specifications File Format Digital Format: PDF Print Quality Readability: High-resolution scans ensuring clear text and diagrams. Binding Type Digital Delivery: Downloadable link provided upon purchase. Paper Type Not Applicable: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Type: Liquid-cooled, 2-stroke, 90-degree V-twin Displacement: 249.2 cc Bore X Stroke: 54.0 mm x 54.5 mm Compression Ratio: 7.5:1 (typical for this model) Performance Horsepower: Approx. 70-75 HP @ 11,000 rpm (varies by market restrictions) Torque: Approx. 43 Nm @ 10,500 rpm Redline: 12,000 rpm (approx.) Fuel System Carburetion: Twin Mikuni TM34 flat-slide carburetors Fuel Delivery: Oil injection system (premix possible with modifications) Ignition System: Digital CDI with electronic ignition 🔧 Transmission Standard Type: 6-speed constant mesh Clutch: Wet, multi-plate clutch Features Gear Ratios: Specific ratios would be detailed in the manual, crucial for performance tuning. Final Drive: Chain drive 📐 Dimensions Exterior Wheelbase: Approx. 1,365 mm (53.7 in) Length: Approx. 2,010 mm (79.1 in) Width: Approx. 720 mm (28.3 in) Height: Approx. 1,135 mm (44.7 in) Weights Dry Weight: Approx. 141 kg (311 lbs) Wet Weight: Approx. 157 kg (346 lbs) Fuel Capacity: 16 Liters (4.2 US gal) 🛡️ Safety Features Ratings Crash Safety: Motorcycle safety ratings are not typically standardized in the same way as cars. Focus is on handling and braking performance. Active Features Braking System: Dual front disc brakes (320mm), single rear disc brake (220mm), typically with 4-piston calipers (e.g., Nissin) on the front. Suspension: Performance-oriented upside-down front forks and adjustable monoshock rear suspension contribute to stability and control. Passive Features Chassis Design: Twin-spar aluminum frame for rigidity and responsiveness. 💡 Technology Features Infotainment System: N/A (None in the modern sense; features a functional analogue instrument cluster) Instrumentation: Analogue speedometer, tachometer, coolant temperature gauge, and essential indicator lights (neutral, turn signals, oil warning). Driver Assistance Features: N/A (None. This is a pure performance sportbike from an era before electronic rider aids.) 🔧 Maintenance Service Intervals Oil Change: Every 3,000-5,000 km or annually (engine oil). Transmission oil typically every 5,000-10,000 km. Chain Maintenance: Lubricate and adjust chain every 500-1,000 km. Spark Plugs: Inspect and clean/replace every 5,000-10,000 km depending on usage and plug type. Fork Oil: Recommended to change every 10,000-15,000 km or as per manual recommendations for optimal damping. Fluid Specifications Engine Oil: 2-stroke synthetic blend or premium mineral oil specifically formulated for high-performance 2-stroke engines (e.g., Motul 800, Castrol TTS). Premix ratio if oil injection bypassed would be 1:30 to 1:50, consult manual. Transmission Oil: API GL-4 or GL-5, SAE 10W-40 or...