🏷️ Basic Information Identification Make: Aprilia Model: RS250 Generation Generation Name: MK1 / MK2 Production Years Covered: 1998-2004 Codes Chassis Codes: AP05 (MK1), AP06 (MK2) 👋 Introduction Market Position Segment: High-performance sportbike, known for its racing heritage and potent two-stroke engine. Competitive Analysis Competitors: Yamaha YZF-R6, Suzuki GSX-R600, Honda CBR600F, Kawasaki Ninja ZX-6R (of the era). Key Features Engine Type: Liquid-cooled, 90-degree V-twin, two-stroke engine, derived from Suzuki RG500 Gamma components. Performance Focus: Emphasis on light weight, sharp handling, and a powerful, exhilarating powerband characteristic of performance two-strokes. Handling Dynamics: Renowned for its agile chassis, excellent suspension feedback, and race-inspired ergonomics. 📋 Manual Details Coverage Areas Market Coverage: Global (primarily European and North American markets) Page Count Estimated Pages: 200-300 (typical for comprehensive service manuals) Manual Type Type: Service and Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine System: Comprehensive coverage of the V-twin two-stroke engine, including top-end rebuilds, bottom-end components, lubrication, cooling, and exhaust systems. Fuel System: Carburetor tuning, jetting, cleaning, fuel pump operation, and fuel tank maintenance. Transmission System: Gearbox disassembly and reassembly, clutch operation and adjustment, gear selection mechanism. Electrical System: Wiring diagrams, ignition system troubleshooting, lighting, charging system (stator, regulator/rectifier), battery maintenance, starter motor. Braking System: Front and rear brake caliper service, master cylinder overhaul, hydraulic line replacement, pad and disc inspection/replacement. Suspension System: Front fork (conventional or upside-down depending on sub-model) disassembly, service, and adjustment; rear shock absorber overhaul and adjustment. Cooling System: Radiator maintenance, coolant replacement, thermostat operation, water pump service. Chassis And Frame: Frame inspection, swingarm bearing service, steering head bearing maintenance. Bodywork And Fairings: Fairing removal and installation, seat, fuel tank mounting, tail section. Procedures Included Routine Maintenance: Oil changes, filter replacements, chain adjustment and lubrication, spark plug checks, air filter cleaning/replacement. Troubleshooting: Diagnostic procedures for common running issues, electrical faults, and mechanical problems. Engine Rebuild: Detailed steps for top-end (piston, rings, cylinder) and bottom-end (crankshaft, bearings) overhaul. Carburetor Service: Complete carburetor cleaning, synchronization, and adjustment procedures. Suspension Tuning: Adjustments for fork preload, compression, and rebound damping; rear shock preload and damping. Electrical Diagnostics: Component testing, wiring continuity checks, fault finding using provided diagrams. Clutch Service: Clutch plate replacement, clutch cable adjustment, hydraulic clutch bleeding (if applicable). Brake System Service: Brake pad replacement, caliper service, bleeding procedures, fluid replacement. Technical Depth Depth: Comprehensive, covering everything from basic maintenance to full engine and chassis rebuilds, including detailed diagnostic information. 📊 Manual Specifications File Format File Type: Portable Document Format (PDF) Searchability: Likely text-searchable if OCR'd properly, allowing for quick access to specific topics. Print Quality Quality: Dependent on the source scan, but good quality scans ensure clear diagrams and text. Binding Type Binding: N/A (Digital PDF format) Paper Type Paper Type: N/A (Digital PDF format) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 90° V-twin, 2-stroke Displacement: 249 cc Bore X Stroke: 54.0 mm x 54.5 mm Compression Ratio: 7.1:1 Valvetrain: Reed valve induction Ignition System: Digital CDI with electronic power jet control Performance Horsepower: Approx. 70-73 hp @ 11,000 rpm (varies slightly by market/tuning) Torque: Approx. 29 lb-ft (39 Nm) @ 10,500 rpm Fuel System Carburetors: 2 x Mikuni TM34SS flat-slide carburetors Fuel Delivery: Petcock with vacuum operation Oil Delivery: Automatic oil injection Lubrication System: Premix or Automatic Oil Injection 🔧 Transmission Standard Type: 6-speed, constant mesh Clutch: Wet, multi-plate Features Gear Ratios: Refer to manual for specific gear ratios (e.g., 1st: 2.615, 2nd: 1.941, 3rd: 1.556, 4th: 1.333, 5th: 1.182, 6th: 1.043) Final Drive: Chain drive Transmission Oil: API GL-4, SAE 80W/90 (refer to manual for exact specification and capacity) 📐 Dimensions Exterior Length: Approx. 1,985 mm (78.1 in) Width: Approx. 710 mm (28.0 in) Height: Approx. 1,140 mm (44.9 in) Wheelbase: Approx. 1,385 mm (54.5 in) Weights Dry Weight: Approx. 143 kg (315 lbs) Wet Weight: Approx. 166 kg (366 lbs) (with fluids) Fuel Capacity: 16 liters (4.2 US gal) Reserve Fuel: Approx. 3 liters (0.8 US gal) 🛡️ Safety Features Ratings Crash Safety: N/A (Motorcycle safety ratings are not standardized in the same way as cars; focus is on rider protection and handling). Active Features Braking: Dual front disc brakes, single rear disc brake. ABS was not a common option on this model. Suspension: Performance-oriented suspension provides stability and feedback for safe control. Passive Features Chassis Design: Sturdy aluminum twin-spar frame contributes to rider confidence. 💡 Technology Features Infotainment Features: N/A (This model predates modern infotainment systems. Features are purely mechanical and performance-oriented.) Driver Assistance Features: N/A (No electronic driver aids such as ABS or traction control were standard on this model.) 🔧 Maintenance Service Intervals Oil Change: Every 3,000-5,000 km (1,800-3,000 miles) or annually, depending on usage and oil type. Transmission oil every 8,000-10,000 km (5,000-6,000 miles). Chain Maintenance: Lubricate and check tension every 500-800 km (300-500 miles). Spark Plugs: Inspect every...