🏷️ Basic Information Identification Make: Aprilia Model: RS 250 Model Years Covered: 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002 Codes Product Code: APRILIA-RS250-9502-SRM 👋 Introduction Market Position Motorcycle Segment: Lightweight Supersport / Two-Stroke Performance Competitive Analysis Key Competitors: Yamaha YZF-R25, Kawasaki ZXR250, Honda CBR250RR, Suzuki RGV250. Key Features Vehicle Appeal: Renowned for its potent 2-stroke performance, agile handling, and sharp styling, a cult classic among sportbike enthusiasts. 📋 Manual Details Coverage Areas Manual Type: Full Service Repair Manual Language: English Format: Digital Download (PDF) Page Count Estimated Page Count: 300+ 📖 Manual Coverage Systems Covered Engine Mechanics: Complete engine disassembly, inspection, repair, and reassembly procedures for the 2-stroke V-twin engine. Fuel System: Carburetor tuning, cleaning, rebuilding (Mikuni TMX), fuel pump, fuel lines, and tank maintenance. Ignition System: Ignition timing, spark plugs, CDI unit, ignition coils, and wiring diagnostics. Cooling System: Radiator, water pump, thermostat, hoses, coolant type, and bleeding procedures. Exhaust System: Expansion chambers, mufflers, exhaust manifold maintenance and gasket replacement. Transmission: Gearbox disassembly, inspection, repair, clutch operation, and transmission fluid specifications. Chassis And Frame: Frame inspection, steering head bearing service, swingarm pivot maintenance, and rear shock linkage. Suspension Front: Front fork service, oil change, seal replacement, damping adjustments (Showa forks). Suspension Rear: Monoshock rear suspension service, linkage lubrication, and spring preload adjustment. Brakes Front: Brake caliper service, pad replacement, disc inspection, master cylinder overhaul, and bleeding procedures. Brakes Rear: Rear brake caliper service, pad replacement, disc inspection, and bleeding procedures. Wheels And Tires: Wheel bearing service, tire pressure recommendations, and wheel removal/installation. Electrical System: Wiring diagrams, battery maintenance, lighting system, starter motor, and charging system diagnostics. Bodywork And Fairings: Fairing removal, installation, and minor bodywork repair guidance. Procedures Included Routine Maintenance: Oil changes, filter replacements, chain adjustment, lubrication points, and bolt torque checks. Troubleshooting Guides: Detailed diagnostic procedures for common starting, running, and electrical issues. Engine Rebuild: Step-by-step instructions for complete engine teardown and rebuild, including piston, ring, and cylinder head service. Carburetor Tuning: Jetting charts, idle speed adjustments, and mixture control guidance for optimal performance. Suspension Adjustment: Guidance on setting sag, rebound, and compression damping for various riding conditions. Brake System Overhaul: Instructions for rebuilding brake calipers, master cylinders, and ensuring proper brake fluid maintenance. Electrical Diagnostics: Troubleshooting common electrical faults using wiring diagrams and multimeter testing. Technical Depth Depth Of Coverage: Comprehensive, from basic rider maintenance to complete engine and gearbox rebuilds. Suitable for home mechanics and professional workshops. 📊 Manual Specifications File Format File Type: PDF Searchable Text: Yes Printable: Yes Print Quality Image Resolution: High-resolution scans of original diagrams and images. Binding Type Binding: N/A (Digital) Paper Type Paper Quality: N/A (Digital) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 2-stroke, 90-degree V-twin Displacement: 249 cc (15.2 cu in) Bore X Stroke: 54.0 mm x 54.5 mm Compression Ratio: 7.1:1 Power Output Hp: 70.0 HP @ 11,000 rpm (claimed) Torque Lb-Ft: 27.5 lb-ft @ 10,000 rpm (claimed) Fuel System Carburetors: Dual Mikuni TMX30 flat-slide carburetors Fuel Delivery: Carbureted with automatic oil injection Lubrication Oil Type: 2-stroke Premix Oil (separate injection system) Ignition Ignition System: Digital CDI Cooling System Cooling Method: Liquid-cooled 🔧 Transmission Standard Transmission Type: 6-speed constant mesh Clutch Type: Wet, multi-plate Features Gear Ratios: See manual for specific gear ratios Final Drive: Chain drive Fluid Specifications Transmission Fluid Type: API GL-4, SAE 80W-90 gear oil (refer to manual for exact spec and capacity) 📐 Dimensions Exterior Length: Approx. 1970 mm (77.6 in) Width: Approx. 700 mm (27.6 in) Height: Approx. 1100 mm (43.3 in) Wheelbase: Approx. 1365 mm (53.7 in) Weights Dry Weight: Approx. 142 kg (313 lbs) Wet Weight: Approx. 165 kg (364 lbs) Tires And Wheels Front Tire Size: 120/70ZR17 Rear Tire Size: 160/60ZR17 Wheel Bolt Pattern: N/A (cast alloy wheels) 🛡️ Safety Features Ratings Safety Features: Dual front disc brakes, single rear disc brake, responsive chassis, and rider-focused ergonomics. Active Features Braking System: Twin piston calipers front, single piston caliper rear. Braided steel brake lines. Passive Features Frame Type: Aluminum twin-spar frame. 💡 Technology Features Infotainment Infotainment System: N/A (Performance motorcycle of its era) Driver Assistance ABS Availability: No ABS Connectivity Bluetooth Connectivity: No Engine Management Engine Management System: Basic CDI ignition, mechanical power valves. 🔧 Maintenance Service Intervals Oil Change Interval: Refer to manual for specific mileage/time intervals. Typically every 3,000-5,000 km for synthetic motorcycle oil. Spark Plug Replacement: Refer to manual. Typically every 5,000-10,000 km depending on plug type. Chain Lubrication Adjustment: Every 500-1,000 km or as needed based on riding conditions. Fluid Specifications Coolant Type: Ethylene glycol-based antifreeze and distilled water mixture (50/50 recommended). Brake Fluid Type: DOT 4 or DOT 5.1 (refer to manual for specific recommendation). 2-Stroke Oil Type: High-quality 2-stroke synthetic or semi-synthetic oil specifically designed for high-performance engines. Known Issues Common Problems: Worn reed valves, carburetor float issues, crank seal leaks, exhaust...