🏷️ Basic Information Identification Make: Aprilia Model: RS250 Generation Applicable Years: 1995-2004 Codes Chassis Codes: AP04, AP07, AP09 👋 Introduction Market Position Target Audience: Aprilia RS250 owners and independent motorcycle technicians Purpose: To provide the same level of technical information as an authorized dealer service department Competitive Analysis Value Proposition: Empowers owners and independent shops to perform professional-level maintenance and repairs, reducing reliance on dealerships Key Features Editorial Approach: Clear, step-by-step instructions with accompanying diagrams and illustrations Diagnostic Focus: Emphasis on efficient troubleshooting and accurate diagnosis 📋 Manual Details Coverage Areas Primary Coverage: Complete service and repair for Aprilia RS250 motorcycles Regional Variations Covered: European, North American, and Japanese market specifications Page Count Estimated Pages: 350-450 Manual Type Type: Factory Service Manual (FSM) Language Language: English Format Format: Printed Manual 📖 Manual Coverage Systems Covered Engine: 2-stroke V-twin, carburetion, exhaust, cooling system Transmission: 6-speed gearbox, clutch assembly, gear shifting mechanism Chassis And Suspension: Frame, front forks (Öhlins/Marzocchi), rear shock absorber (Sachs/Öhlins), swingarm, steering head Brakes: Front dual disc (Brembo), rear single disc (Brembo), master cylinders, calipers, fluid types Electrical System: Ignition system, charging system (stator, regulator/rectifier), lighting, starting system, wiring diagrams Fuel System: Carburetors (Dell'Orto PHBH 28/30), fuel lines, fuel tank, petcock Bodywork: Fairings, seat, fuel tank, tail section, mounting hardware Procedures Included Routine Maintenance: Oil changes, chain adjustment, brake fluid flush, air filter cleaning/replacement, spark plug replacement Engine Overhaul: Top-end rebuild (piston, rings, cylinder), bottom-end rebuild (crankshaft, bearings), engine disassembly/assembly Suspension Adjustment: Fork preload, compression, rebound damping; rear shock preload, compression, rebound damping Carburetor Tuning: Synchronization, jetting adjustments, idle speed setting Troubleshooting: Diagnostic charts for common running issues, electrical faults, and mechanical problems Special Tools: Identification and usage of Aprilia-specific service tools Technical Depth Depth: Comprehensive, covering from basic adjustments to full engine and chassis rebuilds 📊 Manual Specifications File Format Print Quality: High-resolution printing on durable paper stock Binding Type Binding: Comb binding or Saddle-stitched, designed for lay-flat use Paper Type Paper Quality: Glossy, oil-resistant paper ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 2-stroke, V-twin Displacement: 249 cc Bore X Stroke: 54 x 54.5 mm Compression Ratio: 12.9:1 Valve Mechanism: Reed valve induction (per cylinder) Cooling System: Pressurized liquid cooling with electric fan Performance Horsepower Max: 70 hp (approx. at 11,000 rpm) - Euro Spec Torque Max: 27 lb-ft (approx. at 10,500 rpm) Fuel System Carburetors: 2 x Dell'Orto PHBH 28 (or PHBH 30 for later models) Fuel Type: Unleaded gasoline, minimum 98 RON (premium unleaded) Oil Mixture System: Automatic oil injection system Fluid Specifications Engine Oil Type: Fully synthetic 2-stroke oil, JASO FD or ISO-L-EGD compliant Coolant Type: Ethylene glycol based coolant with anti-corrosion additives (50/50 mix with distilled water) 🔧 Transmission Standard Transmission Type: 6-speed sequential constant mesh Features Clutch Type: Wet multi-plate clutch Final Drive: O-ring sealed chain, 520 pitch Fluid Specifications Transmission Oil Type: API GL-4 SAE 80W/90 gear oil Transmission Oil Capacity: Approx. 800 ml 📐 Dimensions Exterior Length: Approx. 1940 mm Width: Approx. 720 mm Height: Approx. 1135 mm Wheelbase: Approx. 1370 mm Weights Dry Weight: Approx. 140 kg Wet Weight: Approx. 155 kg Fuel Tank Capacity: 16 Liters 🛡️ Safety Features Ratings Safety Standards: Compliance with relevant European (CE) and US (EPA) emissions and safety standards for its era Active Features Braking System: High-performance Brembo brake system with braided steel lines Suspension Adjustability: Fully adjustable front forks and rear shock for optimal handling and stability Passive Features Chassis Design: Lightweight aluminum twin-spar frame for rigidity and responsive handling 💡 Technology Features Infotainment Display: Analog tachometer and speedometer, basic warning lights Driver Assistance Electronic Aids: None (designed for pure rider feedback) 🔧 Maintenance Service Intervals Oil Change: Every 5,000 km or annually (whichever comes first) Chain Adjustment: Every 1,000 km or as needed Spark Plug Replacement: Every 10,000 km Air Filter Cleaning: Every 5,000 km Brake Fluid Flush: Every 2 years or as per manual recommendation Fluid Specifications Fork Oil Type: SAE 7.5W or 10W fork oil (check manual for specific model year) Fork Oil Capacity: Approx. 450 ml per leg (check manual for precise volume) Known Issues Common Problems: Carburetor synchronization drift, power valve sticky operation, starter motor issues, aging electrical connectors Performance Tuning: Sensitivity to correct jetting and exhaust modifications 📚 Vehicle History Brand Heritage Manufacturer: Aprilia S.p.A., Italian manufacturer known for racing pedigree Model Evolution Heritage: Successor to the legendary Aprilia AF1 and RS250 GP racing motorcycles Key Changes 1995-2004: Engine tuning, suspension upgrades (Öhlins options), minor styling revisions, carburetor changes (Dell'Orto 28mm to 30mm), improved chassis components Production Production Period: 1995 - 2004 Production Location: Noale, Italy 🏆 Awards & Recognition Recognitions Sportbike Classification: Highly regarded as one of the best 250cc sportbikes of its era, praised for handling and performance Racing Legacy: Direct lineage from Aprilia's successful Grand Prix racing machines