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Aprilia RS 250 2006 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Aprilia Model: RS 250 Year: 2006 Generation Generation Identifier: 2nd Generation / MK2 Codes Vin Code: Refer to VIN plate for specific engine/frame codes 👋 Introduction Market Position Segment: High-performance sportbike, known for its 2-stroke engine and racing heritage Competitive Analysis Competitors: Yamaha YZF-R6, Suzuki GSX-R600, Honda CBR600RR (though the RS250's 2-stroke nature positioned it somewhat uniquely) Key Features Engine Type: Liquid-cooled, 2-stroke, V-twin (derived from Suzuki RGV250) Performance Focus: Agile handling, strong mid-range power delivery, track-oriented performance 📋 Manual Details Coverage Areas Primary Coverage: Comprehensive service and repair for Aprilia RS 250 (2006 model year) Secondary Coverage: Includes routine maintenance, troubleshooting, and detailed repair procedures Page Count Estimated Pages: Likely 300-500 pages (typical for comprehensive service manuals, specific count not provided in product description) Manual Type Type: Factory Service Repair Manual Language Language: English (implied by product description) Format Format: PDF 📖 Manual Coverage Systems Covered Engine Systems: Engine assembly/disassembly, cylinder heads, pistons, crankshaft, lubrication, cooling, ignition, exhaust Fuel System: Carburetor system, fuel delivery, fuel tank, fuel lines Cooling System: Radiator, cooling fan, coolant circuits, water pump Electrical System: Wiring diagrams, battery, charging system, starting system, lighting, instrumentation, ignition system Chassis Systems: Frame, suspension (front and rear), steering, brakes (front and rear), wheels, tires Bodywork: Fairings, seat, fuel tank, body panels, graphics (likely included in general servicing) Procedures Included Maintenance: Periodic maintenance, tune-up procedures, fluid changes, filter replacement, chain adjustment, brake bleeding Troubleshooting: Diagnostic procedures for common and uncommon issues Repair: Detailed step-by-step instructions for component repair and replacement Installation: Likely covers installation of genuine Aprilia accessories or replacement parts Technical Depth Depth: Comprehensive from basic maintenance to advanced diagnostics and engine rebuilds Detail Level: Step-by-step diagrams, torque specifications, fluid capacities, wiring schematics 📊 Manual Specifications File Format Compatibility: All versions of Windows & Mac Requirements: Adobe PDF Reader & WinZip Print Quality Zoom Functionality: YES (Zoom In/Out) Binding Type Binding: Digital (PDF) Paper Type Paper Type: Not Applicable (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 2-stroke, V-twin Displacement: 249 cc (249cc) Bore X Stroke: 54 x 54.5 mm (typical for this engine family) Power Output: Approx. 70-75 hp at 11,000 rpm (specific to model and market, but typical for this generation) Torque Output: Approx. 27-30 lb-ft at 10,000 rpm (typical) Performance Redline: 12,500 rpm (approximate, very high for a 2-stroke) Compression Ratio: 7.8:1 (typical) Fuel System Carburetion: Twin 32mm Mikuni TM Flat Slide Carburetors Fuel Type: Unleaded gasoline (minimum 95 octane recommended) Oil Mixture: Pre-mix or Autolube system (manual will detail which is applicable and oil type) 🔧 Transmission Standard Type: 6-speed constant mesh sequential gearbox Optional Optional Gearbox: N/A (Standard for this model) Features Clutch Type: Wet multi-plate clutch Final Drive: Chain drive 📐 Dimensions Exterior Length: Approx. 1975 mm (77.75 in) Width: Approx. 705 mm (27.75 in) Height: Approx. 1090 mm (42.9 in) Wheelbase: Approx. 1375 mm (54.1 in) Weights Dry Weight: Approx. 130 kg (286.6 lbs) Wet Weight: Approx. 145 kg (319.7 lbs) (with fluids) Fuel Tank Capacity: 16 liters (4.2 US gal) 🛡️ Safety Features Ratings Safety Rating: Motorcycle safety standards apply; specific crash test ratings not applicable Active Features Braking System: Dual front disc brakes, single rear disc brake Suspension: Upside-down telescopic front fork, progressive linkage rear monoshock (adjustable) Passive Features Lighting: Halogen headlight, LED tail light 💡 Technology Features Infotainment Infotainment System: Not Applicable (Performance Sportbike Focus) Driver Assistance Driver Assistance Features: Not Applicable (Performance Sportbike Focus) Connectivity Connectivity Features: Not Applicable (Performance Sportbike Focus) 🔧 Maintenance Service Intervals Oil Change: Refer to manual for specific mileage/time intervals (typically every 3,000-5,000 km for 2-strokes) Spark Plug Replacement: Refer to manual for specific mileage/time intervals (critical for 2-strokes, often around 5,000-10,000 km) Chain Lubrication Adjustment: Regular checks recommended, adjust as needed based on wear Fluid Specifications Engine Oil Type: Fully synthetic 2-stroke racing oil (e.g., Motul 800 2T, Castrol TTS) – manual will specify grade and ratio Coolant Type: Ethylene glycol based coolant with corrosion inhibitors (e.g., Motul Motocool Expert) – typically a 50/50 mix with distilled water Brake Fluid Type: DOT 4 or DOT 5.1 (refer to manual for confirmation and replacement intervals) Fork Oil Type: Suspension fluid (e.g., Showa SS-07, Motul Fork Oil Expert) – manual will specify viscosity (e.g., SAE 10W) Known Issues Common Problems: Carburetor tuning sensitivity, potential for carbon buildup in exhaust ports, clutch wear, power valve issues if not maintained Reliability Factors: Generally reliable when properly maintained, high-strung nature requires diligent upkeep 📚 Vehicle History Brand Heritage Brand Focus: Italian manufacturer with a strong racing pedigree, particularly in Grand Prix motorcycle racing Model Evolution Development: Based on the highly successful Suzuki RGV250 Gamma platform, re-engineered and styled by Aprilia Generations: Two main generations: MK1 (dual headlights, older styling) and MK2 (single headlight, updated fairings, 2003-2008) Production Production Years: Approximately...
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Aprilia RS 250 2006 Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
RS 250
Year:
2006
Generation
Generation Identifier:
2nd Generation / MK2
Codes
Vin Code:
Refer to VIN plate for specific engine/frame codes
👋 Introduction
Market Position
Segment:
High-performance sportbike, known for its 2-stroke engine and racing heritage
Competitive Analysis
Competitors:
Yamaha YZF-R6, Suzuki GSX-R600, Honda CBR600RR (though the RS250's 2-stroke nature positioned it somewhat uniquely)
Key Features
Engine Type:
Liquid-cooled, 2-stroke, V-twin (derived from Suzuki RGV250)
Performance Focus:
Agile handling, strong mid-range power delivery, track-oriented performance
📋 Manual Details
Coverage Areas
Primary Coverage:
Comprehensive service and repair for Aprilia RS 250 (2006 model year)
Secondary Coverage:
Includes routine maintenance, troubleshooting, and detailed repair procedures
Page Count
Estimated Pages:
Likely 300-500 pages (typical for comprehensive service manuals, specific count not provided in product description)
Manual Type
Type:
Factory Service Repair Manual
Language
Language:
English (implied by product description)
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine assembly/disassembly, cylinder heads, pistons, crankshaft, lubrication, cooling, ignition, exhaust
Fuel System:
Carburetor system, fuel delivery, fuel tank, fuel lines
Cooling System:
Radiator, cooling fan, coolant circuits, water pump
Electrical System:
Wiring diagrams, battery, charging system, starting system, lighting, instrumentation, ignition system
Chassis Systems:
Frame, suspension (front and rear), steering, brakes (front and rear), wheels, tires
Bodywork:
Fairings, seat, fuel tank, body panels, graphics (likely included in general servicing)
Procedures Included
Maintenance:
Periodic maintenance, tune-up procedures, fluid changes, filter replacement, chain adjustment, brake bleeding
Troubleshooting:
Diagnostic procedures for common and uncommon issues
Repair:
Detailed step-by-step instructions for component repair and replacement
Installation:
Likely covers installation of genuine Aprilia accessories or replacement parts
Technical Depth
Depth:
Comprehensive from basic maintenance to advanced diagnostics and engine rebuilds
Detail Level:
Step-by-step diagrams, torque specifications, fluid capacities, wiring schematics
📊 Manual Specifications
File Format
Compatibility:
All versions of Windows & Mac
Requirements:
Adobe PDF Reader & WinZip
Print Quality
Zoom Functionality:
YES (Zoom In/Out)
Binding Type
Binding:
Digital (PDF)
Paper Type
Paper Type:
Not Applicable (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, 2-stroke, V-twin
Displacement:
249 cc (249cc)
Bore X Stroke:
54 x 54.5 mm (typical for this engine family)
Power Output:
Approx. 70-75 hp at 11,000 rpm (specific to model and market, but typical for this generation)
Torque Output:
Approx. 27-30 lb-ft at 10,000 rpm (typical)
Performance
Redline:
12,500 rpm (approximate, very high for a 2-stroke)
Compression Ratio:
7.8:1 (typical)
Fuel System
Carburetion:
Twin 32mm Mikuni TM Flat Slide Carburetors
Fuel Type:
Unleaded gasoline (minimum 95 octane recommended)
Oil Mixture:
Pre-mix or Autolube system (manual will detail which is applicable and oil type)
🔧 Transmission
Standard
Type:
6-speed constant mesh sequential gearbox
Optional
Optional Gearbox:
N/A (Standard for this model)
Features
Clutch Type:
Wet multi-plate clutch
Final Drive:
Chain drive
📐 Dimensions
Exterior
Length:
Approx. 1975 mm (77.75 in)
Width:
Approx. 705 mm (27.75 in)
Height:
Approx. 1090 mm (42.9 in)
Wheelbase:
Approx. 1375 mm (54.1 in)
Weights
Dry Weight:
Approx. 130 kg (286.6 lbs)
Wet Weight:
Approx. 145 kg (319.7 lbs) (with fluids)
Fuel Tank Capacity:
16 liters (4.2 US gal)
🛡️ Safety Features
Ratings
Safety Rating:
Motorcycle safety standards apply; specific crash test ratings not applicable
Active Features
Braking System:
Dual front disc brakes, single rear disc brake
Suspension:
Upside-down telescopic front fork, progressive linkage rear monoshock (adjustable)
Passive Features
Lighting:
Halogen headlight, LED tail light
💡 Technology Features
Infotainment
Infotainment System:
Not Applicable (Performance Sportbike Focus)
Driver Assistance
Driver Assistance Features:
Not Applicable (Performance Sportbike Focus)
Connectivity
Connectivity Features:
Not Applicable (Performance Sportbike Focus)
🔧 Maintenance
Service Intervals
Oil Change:
Refer to manual for specific mileage/time intervals (typically every 3,000-5,000 km for 2-strokes)
Spark Plug Replacement:
Refer to manual for specific mileage/time intervals (critical for 2-strokes, often around 5,000-10,000 km)
Chain Lubrication Adjustment:
Regular checks recommended, adjust as needed based on wear
Fluid Specifications
Engine Oil Type:
Fully synthetic 2-stroke racing oil (e.g., Motul 800 2T, Castrol TTS) – manual will specify grade and ratio
Coolant Type:
Ethylene glycol based coolant with corrosion inhibitors (e.g., Motul Motocool Expert) – typically a 50/50 mix with distilled water
Brake Fluid Type:
DOT 4 or DOT 5.1 (refer to manual for confirmation and replacement intervals)
Fork Oil Type:
Suspension fluid (e.g., Showa SS-07, Motul Fork Oil Expert) – manual will specify viscosity (e.g., SAE 10W)
Known Issues
Common Problems:
Carburetor tuning sensitivity, potential for carbon buildup in exhaust ports, clutch wear, power valve issues if not maintained
Reliability Factors:
Generally reliable when properly maintained, high-strung nature requires diligent upkeep
📚 Vehicle History
Brand Heritage
Brand Focus:
Italian manufacturer with a strong racing pedigree, particularly in Grand Prix motorcycle racing
Model Evolution
Development:
Based on the highly successful Suzuki RGV250 Gamma platform, re-engineered and styled by Aprilia
Generations:
Two main generations: MK1 (dual headlights, older styling) and MK2 (single headlight, updated fairings, 2003-2008)
Production
Production Years:
Approximately 1998-2008 (specific year coverage for this manual is 2006)
Manufacturing Location:
Italy
🏆 Awards & Recognition
Recognitions
Critical Acclaim:
Widely praised for its handling, sharp styling, and exciting 2-stroke performance; often considered a modern classic
Ratings
Performance Reviews:
Consistently rated highly by motorcycle publications for its agility and track capabilities
Certifications
Manual Certification:
Official Dealer Workshop equivalent
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