🏷️ Basic Information Identification Make: Aprilia Model: RS250 Year: 2004 Codes Vin Prefix: ZDM525 👋 Introduction Market Position Segment: High-performance sportbike, directly competing with other 250cc two-stroke legends of its era. Competitive Analysis Key Competitors: Yamaha YZF-R25, Honda CBR250RR (MC22), Kawasaki ZXR250, Suzuki RGV250. Key Features Engine Type: Torquey and rev-happy 2-stroke V-twin, renowned for its sound and performance. Handling: Excellent chassis dynamics, lightweight, and sharp handling characteristics, derived from racing technology. Design: Aggressive and aerodynamic styling, reflecting its racing pedigree. 📋 Manual Details Coverage Areas Models Covered: All Aprilia RS250 2004 models, engines, trim, and transmission types. Page Count Estimated Pages: Approximately 300-400 pages (typical for comprehensive workshop manuals). Manual Type Type: Workshop Repair Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Detailed diagnosis and repair of the 2-stroke V-twin engine, including top-end, bottom-end, cooling, and lubrication systems. Fuel System: Carburetor adjustment and overhaul (likely Mikuni TM30-1), fuel pump, fuel lines, and tank maintenance. Ignition System: CDI ignition, spark plug specifications, troubleshooting ignition faults. Transmission: 6-speed sequential gearbox, clutch assembly (wet multi-plate), shift mechanism, and gearbox oil specifications. Chassis Frame: Frame inspection, swingarm, steering head bearings, and suspension mounting points. Suspension Front: Front fork (likely Showa or Marzocchi) overhaul, damping adjustments, oil levels and types, seal replacement. Suspension Rear: Monoshock rear suspension, linkage system, shock absorber adjustment and overhaul, spring pre-load. Brakes Front: Dual disc front brakes, caliper overhaul, master cylinder, brake line replacement, fluid specifications (DOT 4), bleeding procedures. Brakes Rear: Single disc rear brake, caliper and master cylinder service, fluid specifications, bleeding. Electrical System: Wiring diagrams, battery maintenance, charging system (stator and regulator/rectifier), lighting, starter motor, and all switches/sensors. Cooling System: Radiator, fan, water pump, coolant specifications and replacement, bleeding the system. Exhaust System: Exhaust pipe and silencer removal, inspection, and potential minor repairs. Bodywork Fairings: Fairing removal and installation, seat, fuel tank, and other body panels. Procedures Included Routine Maintenance: Oil changes, filter replacements, chain adjustment, spark plug replacement, air filter cleaning/replacement, general inspection. Troubleshooting: Systematic diagnostic procedures for common and uncommon issues, fault finding charts. Engine Rebuild: Piston, ring, cylinder, crankshaft, and bearing replacement procedures, torque specifications for all fasteners. Transmission Overhaul: Gearbox disassembly, inspection of gears and shift forks, reassembly. Suspension Service: Fork seal replacement, rear shock absorber servicing. Brake System Maintenance: Brake pad replacement, caliper service, bleeding, fluid flush. Electrical Diagnostics: Using multimeter, testing sensors, component testing, wiring harness repair. Technical Depth Depth: Comprehensive: Covers basic maintenance to complete engine and gearbox overhauls, with detailed diagnostic trees and torque specifications. 📊 Manual Specifications File Format PDF Quality: High-resolution, searchable text, printable pages. Print Quality Print Recommendation: Optimized for digital viewing and printing individual pages. Recommend professional binding if a physical copy is desired. Binding Type Binding: Digital (PDF Download) - No physical binding. Paper Type Paper Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 493cc, 90-degree V-twin, 2-stroke Bore X Stroke: 51.5 mm x 48.6 mm Compression Ratio: 7.2:1 Valvetrain: Reed valve induction Carburetion: Twin Mikuni TM30-1 flat-slide carburetors Power Output: Approx. 70 PS (51.5 kW) @ 11,000 rpm (Varies slightly by market and tuning) Torque Output: Approx. 42 Nm (31 lb-ft) @ 10,000 rpm Lubrication System: Premix or separate oil injection (automatic oil pump) Fuel System Fuel Type: Unleaded gasoline (minimum 91 RON/87 AKI) 🔧 Transmission Standard Type: 6-speed sequential manual transmission Clutch: Wet multi-plate clutch Features Gear Ratios: Refer to manual for specific ratios (typical 1st: ~2.76, 6th: ~0.91) Final Drive: Chain drive (520 O-ring chain) Transmission Oil: API GL-4, SAE 75W/90 synthetic gear oil (capacity approx. 0.8 L) 📐 Dimensions Exterior Length: Approx. 1980 mm (78.0 in) Width: Approx. 700 mm (27.6 in) Height: Approx. 1130 mm (44.5 in) Wheelbase: Approx. 1370 mm (53.9 in) Seat Height: Approx. 810 mm (31.9 in) Weights Dry Weight: Approx. 140 kg (308.6 lbs) Wet Weight: Approx. 165 kg (363.8 lbs) Fuel Capacity: 16 Liters (4.2 US gal) 🛡️ Safety Features Ratings Safety Standards: Designed to meet then-current European and North American motorcycle safety regulations. Active Features Braking System: Powerful dual front discs and single rear disc for effective stopping power. Tires: Sport-oriented tires providing good grip. Passive Features Frame Construction: Sturdy twin-spar aluminum frame for chassis rigidity and rider confidence. 💡 Technology Features Infotainment Instrument Cluster: Analog tachometer and speedometer, along with essential indicator lights. No advanced digital infotainment. Driver Assistance Assistance Systems: No electronic rider aids such as ABS or traction control were standard on this model. Focus is on rider input and mechanical grip. Connectivity Connectivity Features: N/A - Analog systems only. 🔧 Maintenance Service Intervals Oil Change Engine: Every 3,000-5,000 km (1,800-3,100 miles) or annually, whichever comes first. Inspect regularly. Spark Plug Replacement: Every 5,000-10,000 km (3,100-6,200 miles), depending on usage and plug type. Air Filter Service: Inspect every...