🏷️ Basic Information Identification Make: Aprilia Model: RS 250 Model Code: RS 250 (MK1 and MK2) Codes Engine Code Range: Rotax 257 (various iterations) 👋 Introduction Market Position Positioning: High-performance, two-stroke sportbike that competed directly with Japanese 250cc GP replicas. Competitive Analysis Competitors: Yamaha YZF-R25, Honda CBR250RR, Kawasaki ZXR250, Suzuki RG250 Gamma. Key Features Engine Type: Liquid-cooled, V-twin, two-stroke engine, derived from Suzuki RGV250 components. Chassis Design: Twin-spar aluminum frame, lightweight construction, excellent handling characteristics. Performance Focus: Track-focused performance, sharp handling, potent power delivery. Target Audience Owner Profile: Enthusiast riders seeking a classic, capable 250cc two-stroke sportbike for spirited riding and track days. 📋 Manual Details Coverage Areas Years Covered: 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002 Page Count Estimated Page Count: 400+ Manual Type Type: Factory Service Manual / Repair Manual Language Language: English Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Engine: Complete overhaul, top-end rebuild, bottom-end assembly, cooling system, lubrication system. Fuel System: Carburetor tuning and overhaul (Dell'Orto PHBH 28 AS), fuel pump, fuel lines, fuel tank. Ignition System: CDI ignition, spark plugs, timing, wiring diagrams. Transmission: Six-speed gearbox, clutch assembly (hydraulic actuation), gear selection mechanism, lubrication. Chassis And Frame: Frame inspection and repair, steering head bearings, swingarm, linkages. Suspension: Front fork (Showa or Marzocchi depending on year/spec) overhaul, adjustments, rear shock absorber (Ohlins or Sachs) service. Brakes: Front and rear disc brakes (Brembo calipers), hydraulic system, bleeding procedures, pad replacement, master cylinder overhaul. Electrical System: Wiring diagrams, battery, charging system, lighting, instrumentation, starter motor, fuses. Bodywork And Fairings: Fairing removal and installation, seat, fuel tank mounting, cosmetic repairs. Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, chain adjustment, spark plug checks, coolant checks. Troubleshooting: Diagnostic flowcharts for common starting, running, and electrical issues. Repair: Step-by-step instructions for component removal, overhaul, and reassembly. Diagnostics: Identification of potential faults and their causes. Torque Specifications: All critical fasteners torqued to factory specifications. Technical Depth Depth: Comprehensive from basic checks to full engine and gearbox rebuilds. 📊 Manual Specifications File Format File Quality: High-resolution scans, clear text and diagrams. Searchability: Text-searchable PDF for quick information retrieval. Print Quality Printability: Printable on standard home/office printers. Binding Type Binding: N/A (Digital) Paper Type Paper Quality: N/A (Digital) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 90-degree V-twin, two-stroke Displacement: 249 cc Bore X Stroke: 54.0 mm x 54.5 mm Compression Ratio: 7.0:1 (or similar, varies slightly) Power Output: Approximately 60-65 hp @ 11,000 rpm (market dependent) Torque: Approximately 38-40 Nm @ 10,000 rpm (market dependent) Performance Top Speed: 130+ mph (approximate) Fuel System Carburetors: 2 x Dell'Orto PHBH 28 AS (or similar) Fuel Type: Unleaded gasoline (minimum 95 RON recommended), 2-stroke oil for premix or injection. Oil Injection: Automatic oil injection system. 🔧 Transmission Standard Type: 6-speed, constant mesh Clutch: Wet multi-plate, hydraulic actuation Features Gear Ratios: Specific ratios detailed in the manual, optimized for sport riding. Final Drive: Chain drive, 520 pitch (typical) 📐 Dimensions Exterior Length: Approximately 1970 mm Width: Approximately 680 mm (excluding mirrors) Height: Approximately 1120 mm Wheelbase: Approximately 1360 mm Weights Dry Weight: Approximately 140 kg Wet Weight: Approximately 155 kg (fully fueled) Fuel Tank Capacity: 16 liters 🛡️ Safety Features Ratings Crash Safety: N/A (Motorcycle, manufacturer-specific testing) Active Features Braking System: Dual front disc brakes with multi-piston calipers, single rear disc brake. Suspension Tuning: Adjustable front forks and rear shock for personalized handling and stability. Passive Features Lighting: Halogen headlight, LED taillight (typical). 💡 Technology Features Infotainment Instrument Cluster: Analog tachometer, speedometer, temperature gauge, neutral indicator, turn signals, oil warning light. Driver Assistance ABS: Not typically equipped with ABS. Connectivity Connectivity Features: N/A (Classic sportbike) 🔧 Maintenance Service Intervals Oil Change Engine: Every 3,000-5,000 km or annually, depending on usage. Chain Lubrication: Every 500-1,000 km or after riding in wet conditions. Spark Plug Inspection: Every 5,000-7,000 km. Top End Rebuild: Recommended between 15,000-25,000 km for optimal performance and longevity, depending on riding style. Fluid Specifications Engine Oil: Specific 2-stroke premix oil (API TC, JASO FD certified) or dedicated injection oil. Manual specifies exact grades. Coolant: Mixture of distilled water and appropriate motorcycle coolant (ethylene glycol-based). Manual specifies ratio and type. Brake Fluid: DOT 4 or DOT 5.1 brake fluid. Transmission Oil: Specific gearbox oil, e.g., SAE 75W/90 or similar, as per Aprilia recommendation. Manual specifies capacity and type. Known Issues Power Valve Sticking: Common in high-mileage two-strokes due to carbon buildup; requires periodic cleaning. Carburetor Sync And Tuning: Requires regular attention for optimal running, especially after rebuilds or modifications. Cooling System Leaks: Hose degradation or radiator issues can occur over time. Clutch Slave Cylinder Leaks: Hydraulic clutch system can develop leaks at the slave cylinder. 📚 Vehicle History Brand Heritage Heritage: Aprilia has a strong racing pedigree in Grand Prix motorcycle racing, particularly in smaller displacement classes. Model Evolution Evolution Phases: The...