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Aprilia RS 250 2008 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Aprilia Model: RS 250 Year: 2008 Codes Chassis Code: AP06 Engine Code Identifier: Rotax 2-stroke V-twin based (development of the Suzuki RG250 Gamma engine) 👋 Introduction Market Position Target Audience: Owners of the Aprilia RS 250 (2008) seeking to perform maintenance, repairs, and diagnostics. Value Proposition: Provides dealer-level technical information, enabling owners to maintain and repair their motorcycles effectively, saving time and money. Competitive Analysis Uniqueness: This manual is positioned as an exact replica of the official dealer workshop manual, offering a depth of information typically not found in aftermarket manuals. Key Features Completeness: Covers every conceivable aspect of the motorcycle's operation and maintenance. Ease Of Use: Designed to be user-friendly with clear instructions and diagrams. Authoritative Source: Represents the same information used by authorized Aprilia technicians. 📋 Manual Details Coverage Areas Coverage Scope: Comprehensive service and repair for all aspects of the Aprilia RS 250 (2008 model year) Page Count Estimated Pages: High (detailed diagrams and extensive procedures suggest over 500 pages) Manual Type Manual Type: Factory Service Repair Manual Language Language: English (primary, as indicated by product description) Format File Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Full engine disassembly, assembly, troubleshooting, overhaul procedures, piston, cylinder, crankshaft, connecting rod, and valve (reed valve) inspection and replacement. Fuel System: Carburetor settings, cleaning, overhaul, fuel pump operation, fuel tank, fuel lines, and petcock servicing. Lubrication System: Oil pump operation, oil injection system troubleshooting, oil tank servicing, and lubricant specifications. Cooling System: Radiator, fan, water pump, coolant specifications, bleeding procedures, and thermostat testing. Electrical System: Wiring diagrams, battery, charging system (stator, regulator/rectifier), ignition system (CDI, spark plugs), lighting system, starter motor, and all electronic components. Chassis Components: Frame inspection, suspension (front forks, rear shock absorber), steering system, wheel bearings, and swingarm. Braking System: Front and rear brake caliper servicing, master cylinder overhaul, brake line replacement, fluid specifications, and bleeding procedures. Clutch System: Clutch lever, cable, and clutch pack inspection, adjustment, and replacement. Exhaust System: Exhaust pipe and silencer inspection, gasket replacement, and performance tuning considerations. Bodywork And Trim: Fairing removal and installation, seat, tank, and other body panel servicing. Procedures Included Tune Up: Complete tune-up procedures including spark plug replacement, air filter cleaning/replacement, carburetor synchronization, and idle speed adjustment. Periodic Maintenance: Scheduled maintenance tasks, fluid changes, chain adjustment, lubrication, and general inspection guidelines. Troubleshooting: Diagnostic guides and step-by-step troubleshooting for common and uncommon issues across all vehicle systems. Overhaul Rebuild: Detailed instructions for complete engine rebuilds, carburetor overhauls, and suspension component overhauls. Electrical Diagnostics: Fault finding for electrical circuits, testing of components, and interpretation of wiring diagrams. Torque Specifications: Specific torque values for all critical fasteners and components. Fluid Capacities: Accurate fluid capacities for engine oil, coolant, transmission fluid (if applicable separately), and brake fluid. Technical Depth Diagnostic Level: Advanced diagnostic procedures with detailed symptom-cause-remedy tables. Repair Complexity: Covers everything from basic maintenance to complete engine and chassis overhauls, suitable for both DIY enthusiasts and professional mechanics. Diagrams Illustrations: Step-by-step diagrams and illustrations for clarity in all procedures. 📊 Manual Specifications File Format Accessibility: Searchable text within PDF for quick information retrieval. Readability: High resolution for clear viewing and zooming capabilities. Portability: Compatible with various devices and operating systems (Windows & Mac). Print Quality Printability: Designed for clear printing of specific pages or the entire manual. Binding Type Digital Format Notes: Delivered as a digital PDF file, no physical binding. Paper Type Digital Format Notes 2: N/A (Digital format) ⚙️ Engine Specifications Primary Engine Engine Type: 2-stroke, V-twin Displacement: 249 cc Bore X Stroke: 54 mm x 54.5 mm Cooling System: Liquid-cooled Reed Valves: Yes, performance-oriented reed valve induction Compression Ratio: Typically around 7.5:1 (subject to specific tuning and model variations, manual will confirm) Performance Horsepower: Approximately 70-75 HP (at crankshaft, manual will detail specific output for 2008 model) Torque: Approximately 40-45 Nm (at crankshaft, manual will detail specific output for 2008 model) Fuel System Carburetion: Dual 32 mm Mikuni flat-slide carburetors (TM32SS) Fuel Type: Unleaded gasoline (min. 95 octane recommended, manual will specify) Lubrication System Oil Delivery: Automatic oil injection system Engine Oil Spec: Two-stroke premix oil (specific API TC or JASO FD grade, manual will confirm) 🔧 Transmission Standard Transmission Type: 6-speed, constant mesh Clutch Type: Wet multi-plate clutch Features Gear Ratios: Detailed gear ratios for all 6 speeds will be provided in the manual. Final Drive: Chain drive Transmission Oil Spec: Specific gear oil viscosity and type (e.g., SAE 80W-90, manual will specify) 📐 Dimensions Exterior Length: Approx. 2,020 mm (manual will provide exact figure) Width: Approx. 720 mm (manual will provide exact figure) Height: Approx. 1,115 mm (manual will provide exact figure) Weights Dry Weight: Approx. 142 kg (manual will provide exact figure) Wet Weight: Approx. 160 kg (with fluids, manual will provide exact figure) Fuel Tank Capacity: Approx. 16...
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Aprilia RS 250 2008 Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
RS 250
Year:
2008
Codes
Chassis Code:
AP06
Engine Code Identifier:
Rotax 2-stroke V-twin based (development of the Suzuki RG250 Gamma engine)
👋 Introduction
Market Position
Target Audience:
Owners of the Aprilia RS 250 (2008) seeking to perform maintenance, repairs, and diagnostics.
Value Proposition:
Provides dealer-level technical information, enabling owners to maintain and repair their motorcycles effectively, saving time and money.
Competitive Analysis
Uniqueness:
This manual is positioned as an exact replica of the official dealer workshop manual, offering a depth of information typically not found in aftermarket manuals.
Key Features
Completeness:
Covers every conceivable aspect of the motorcycle's operation and maintenance.
Ease Of Use:
Designed to be user-friendly with clear instructions and diagrams.
Authoritative Source:
Represents the same information used by authorized Aprilia technicians.
📋 Manual Details
Coverage Areas
Coverage Scope:
Comprehensive service and repair for all aspects of the Aprilia RS 250 (2008 model year)
Page Count
Estimated Pages:
High (detailed diagrams and extensive procedures suggest over 500 pages)
Manual Type
Manual Type:
Factory Service Repair Manual
Language
Language:
English (primary, as indicated by product description)
Format
File Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Full engine disassembly, assembly, troubleshooting, overhaul procedures, piston, cylinder, crankshaft, connecting rod, and valve (reed valve) inspection and replacement.
Fuel System:
Carburetor settings, cleaning, overhaul, fuel pump operation, fuel tank, fuel lines, and petcock servicing.
Lubrication System:
Oil pump operation, oil injection system troubleshooting, oil tank servicing, and lubricant specifications.
Cooling System:
Radiator, fan, water pump, coolant specifications, bleeding procedures, and thermostat testing.
Electrical System:
Wiring diagrams, battery, charging system (stator, regulator/rectifier), ignition system (CDI, spark plugs), lighting system, starter motor, and all electronic components.
Chassis Components:
Frame inspection, suspension (front forks, rear shock absorber), steering system, wheel bearings, and swingarm.
Braking System:
Front and rear brake caliper servicing, master cylinder overhaul, brake line replacement, fluid specifications, and bleeding procedures.
Clutch System:
Clutch lever, cable, and clutch pack inspection, adjustment, and replacement.
Exhaust System:
Exhaust pipe and silencer inspection, gasket replacement, and performance tuning considerations.
Bodywork And Trim:
Fairing removal and installation, seat, tank, and other body panel servicing.
Procedures Included
Tune Up:
Complete tune-up procedures including spark plug replacement, air filter cleaning/replacement, carburetor synchronization, and idle speed adjustment.
Periodic Maintenance:
Scheduled maintenance tasks, fluid changes, chain adjustment, lubrication, and general inspection guidelines.
Troubleshooting:
Diagnostic guides and step-by-step troubleshooting for common and uncommon issues across all vehicle systems.
Overhaul Rebuild:
Detailed instructions for complete engine rebuilds, carburetor overhauls, and suspension component overhauls.
Electrical Diagnostics:
Fault finding for electrical circuits, testing of components, and interpretation of wiring diagrams.
Torque Specifications:
Specific torque values for all critical fasteners and components.
Fluid Capacities:
Accurate fluid capacities for engine oil, coolant, transmission fluid (if applicable separately), and brake fluid.
Technical Depth
Diagnostic Level:
Advanced diagnostic procedures with detailed symptom-cause-remedy tables.
Repair Complexity:
Covers everything from basic maintenance to complete engine and chassis overhauls, suitable for both DIY enthusiasts and professional mechanics.
Diagrams Illustrations:
Step-by-step diagrams and illustrations for clarity in all procedures.
📊 Manual Specifications
File Format
Accessibility:
Searchable text within PDF for quick information retrieval.
Readability:
High resolution for clear viewing and zooming capabilities.
Portability:
Compatible with various devices and operating systems (Windows & Mac).
Print Quality
Printability:
Designed for clear printing of specific pages or the entire manual.
Binding Type
Digital Format Notes:
Delivered as a digital PDF file, no physical binding.
Paper Type
Digital Format Notes 2:
N/A (Digital format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
2-stroke, V-twin
Displacement:
249 cc
Bore X Stroke:
54 mm x 54.5 mm
Cooling System:
Liquid-cooled
Reed Valves:
Yes, performance-oriented reed valve induction
Compression Ratio:
Typically around 7.5:1 (subject to specific tuning and model variations, manual will confirm)
Performance
Horsepower:
Approximately 70-75 HP (at crankshaft, manual will detail specific output for 2008 model)
Torque:
Approximately 40-45 Nm (at crankshaft, manual will detail specific output for 2008 model)
Fuel System
Carburetion:
Dual 32 mm Mikuni flat-slide carburetors (TM32SS)
Fuel Type:
Unleaded gasoline (min. 95 octane recommended, manual will specify)
Lubrication System
Oil Delivery:
Automatic oil injection system
Engine Oil Spec:
Two-stroke premix oil (specific API TC or JASO FD grade, manual will confirm)
🔧 Transmission
Standard
Transmission Type:
6-speed, constant mesh
Clutch Type:
Wet multi-plate clutch
Features
Gear Ratios:
Detailed gear ratios for all 6 speeds will be provided in the manual.
Final Drive:
Chain drive
Transmission Oil Spec:
Specific gear oil viscosity and type (e.g., SAE 80W-90, manual will specify)
📐 Dimensions
Exterior
Length:
Approx. 2,020 mm (manual will provide exact figure)
Width:
Approx. 720 mm (manual will provide exact figure)
Height:
Approx. 1,115 mm (manual will provide exact figure)
Weights
Dry Weight:
Approx. 142 kg (manual will provide exact figure)
Wet Weight:
Approx. 160 kg (with fluids, manual will provide exact figure)
Fuel Tank Capacity:
Approx. 16 liters (manual will confirm exact capacity)
Wheelbase:
Approx. 1,365 mm (manual will provide exact figure)
🛡️ Safety Features
Ratings
Safety Features Focus:
Manual focuses on mechanical and operational safety through correct maintenance and repair procedures.
Active Features
Braking System:
Dual front 320mm discs with 4-piston calipers; single rear 240mm disc with 2-piston caliper. ABS was not standard on this model.
Suspension Performance:
Inverted front forks and adjustable monoshock rear suspension contribute to handling and stability.
Passive Features
Chassis Design:
Stiff twin-spar aluminum frame for rider confidence and control.
💡 Technology Features
Infotainment
Infotainment Systems:
This model predates modern infotainment systems. Focus is on essential vehicle electronics.
Driver Assistance
Driver Assistance Systems:
No electronic driver assistance systems like traction control or ABS (standard) are featured on this model. Safety relies on rider skill and machine maintenance.
Connectivity
Connectivity Features:
No modern connectivity features; focus is on mechanical and electrical systems.
🔧 Maintenance
Service Intervals
Oil Change:
Recommended at intervals specified in the manual, typically every few thousand kilometers or annually.
Spark Plug Check:
Periodic inspection and cleaning/replacement as per manual recommendations (e.g., every 5,000-10,000 km).
Chain Lubrication:
Regular lubrication and adjustment are critical for longevity.
Coolant Flush:
Recommended every 1-2 years to maintain cooling efficiency.
Fluid Specifications
Coolant Type:
Ethylene glycol-based antifreeze, manual will specify capacity and mix ratio.
Brake Fluid Type:
DOT 4 (or DOT 5.1, manual will confirm) hydraulic fluid.
Known Issues
Power Valve Stiction:
Carbon buildup can cause power valves to stick, requiring cleaning and lubrication as detailed in the manual.
Carburetor Performance:
Mikuni carburetors require precise tuning; manual provides settings for optimal performance and reliability.
Electrical Connections:
Corrosion or loose connections can cause intermittent electrical faults, which the manual's wiring diagrams help diagnose.
📚 Vehicle History
Brand Heritage
Aprilia Legacy:
Aprilia has a strong heritage in motorcycle racing, particularly in the 250cc Grand Prix class, which heavily influenced the RS 250's design and performance.
Model Evolution
Rs 250 Lineage:
The RS 250 is a descendant of the legendary Suzuki RG250 Gamma, with Aprilia developing its own engine and chassis based on this influential platform.
Key Milestones:
The RS 250 was produced from 1995 to 2003, with updates and revisions throughout its run. The 2008 mention in the manual title might refer to later documentation or a specific market release; however, the RS 250 production officially ended earlier.
Production
Manufacturing Location:
Italy
🏆 Awards & Recognition
Recognitions
Model Reputation:
The Aprilia RS 250 is highly regarded among enthusiasts for its performance, handling, and authentic 2-stroke racing pedigree.
Ratings
Journal Reviews:
Consistently received positive reviews from motorcycle publications during its production for its sharp handling and potent engine characteristics.
Certifications
Manual Certification:
Indicated as the same manual used by official dealers, implying adherence to factory standards.
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