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Aprilia Leonardo 125-150-250 2003 Service Repair Manual

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🏷️ Basic Information Identification Make: Aprilia Model: Leonardo Model Variant: 125, 150, 250 Model Year: 2003 Codes Chassis Code: AP03 👋 Introduction Market Position Vehicle Segment: Maxi-scooter Target Audience: Urban...
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Aprilia Leonardo 125-150-250 2003 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
Leonardo
Model Variant:
125, 150, 250
Model Year:
2003
Codes
Chassis Code:
AP03
👋 Introduction
Market Position
Vehicle Segment:
Maxi-scooter
Target Audience:
Urban commuters, scooter enthusiasts seeking performance and comfort.
Competitive Analysis
Key Competitors:
Piaggio X9, Suzuki Burgman, Yamaha Majesty, Honda Pantheon.
Key Features
Design Philosophy:
Sporty yet comfortable maxi-scooter design with advanced features for its class.
Aprilia Heritage:
Leverages Aprilia's reputation in performance-oriented motorcycles and scooters.
📋 Manual Details
Coverage Areas
Manual Type:
Service Repair Manual
Language:
English
Format:
Digital (PDF)
Page Count:
Approximately 250 pages (estimated based on typical service manuals for this class of vehicle)
📖 Manual Coverage
Systems Covered
Engine System:
Engine disassembly, assembly, inspection, overhaul, troubleshooting, tuning.
Fuel System:
Carburetor/Fuel Injection system (depending on specific model variant), fuel pump, fuel lines, fuel tank inspection and cleaning.
Ignition System:
Spark plugs, ignition coils, CDI unit, wiring diagram analysis.
Cooling System:
Radiator, coolant hoses, thermostat, fan operation (if applicable).
Transmission System:
Automatic transmission (CVT) operation, belt inspection/replacement, roller weights, clutch assembly.
Braking System:
Front and rear brake caliper service, brake pad replacement, brake fluid flush and bleed, master cylinder inspection.
Suspension System:
Front fork overhaul, rear shock absorber inspection and replacement, bushing checks.
Steering System:
Handlebar assembly, steering bearing inspection and adjustment, linkage checks.
Electrical System:
Battery service, charging system (stator, rectifier/regulator), starter motor, lighting system, wiring diagrams.
Bodywork And Frame:
Panel removal and installation, seat, fairings, chassis inspection.
Procedures Included
Preventative Maintenance:
Scheduled maintenance intervals, fluid changes, filter replacements, general inspection points.
Troubleshooting Guides:
Diagnostic flowcharts for common issues related to engine performance, starting, electrical faults.
Repair Procedures:
Step-by-step instructions for component disassembly, repair, and reassembly.
Diagnostic Techniques:
Methods for identifying malfunctions using visual inspection, test equipment, and symptom analysis.
Specifications Data:
Torque specifications, clearances, fluid capacities, electrical resistance values.
Technical Depth
Depth Level:
Comprehensive (covers from basic maintenance to complete engine rebuilds and electrical system diagnostics).
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Fully searchable text for quick information retrieval.
Printability:
Printable pages for workshop use.
Image Quality:
High-resolution diagrams and illustrations.
Print Quality
Print Format:
Digital reproduction of original factory manual.
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Type 125:
4-stroke, single-cylinder, liquid-cooled, OHC
Displacement 125:
124.9 cc
Bore Stroke 125:
52 mm x 58.6 mm
Engine Type 150:
4-stroke, single-cylinder, liquid-cooled, OHC
Displacement 150:
150 cc (exact displacement may vary slightly based on region, often around 149 cc for European models)
Bore Stroke 150:
57 mm x 58.6 mm
Engine Type 250:
4-stroke, single-cylinder, liquid-cooled, OHC
Displacement 250:
244 cc (Piaggio LEADER engine variant)
Bore Stroke 250:
72 mm x 60 mm
Performance
Horsepower 125:
Approximately 14-15 HP @ 8,000 RPM (varies by market regulation)
Horsepower 150:
Approximately 15-16 HP @ 7,500 RPM (varies by market regulation)
Horsepower 250:
Approximately 21 HP @ 7,500 RPM (varies by market regulation)
Torque 250:
Approximately 20.5 Nm @ 6,000 RPM (varies by market regulation)
Fuel System
Fuel Delivery 125 150:
Carburetor (e.g., Mikuni BS26 or similar, specific to market and emission standards)
Fuel Delivery 250:
Electronic Fuel Injection (EFI) - often uses Piaggio's 4-stroke LEADER engine with EFI
Fuel Type:
Unleaded gasoline
Fuel Tank Capacity:
Approximately 10-12 Liters (varies slightly)
🔧 Transmission
Standard
Transmission Type:
Automatic CVT (Continuously Variable Transmission)
Drive Type:
Belt drive
Optional
Optional Transmission:
N/A (CVT is standard)
Features
Transmission Features:
Smooth acceleration, adaptive gearing for optimal performance and fuel economy.
📐 Dimensions
Exterior
Length:
Approximately 2020 mm
Width:
Approximately 750 mm
Height:
Approximately 1350 mm (including windscreen)
Wheelbase:
Approximately 1420 mm
Weights
Dry Weight 125 150:
Approximately 150-155 kg
Dry Weight 250:
Approximately 165-170 kg
Gross Vehicle Weight Rating Gvwr:
Not explicitly specified, but typically around 300-330 kg including rider and luggage.
Cargo
Underseat Storage:
Sufficient for one full-face helmet and small items.
Rear Rack Provision:
Often equipped with or has provisions for an accessory rear luggage rack.
🛡️ Safety Features
Ratings
Crash Test Results:
N/A (Motorcycle/scooter safety standards differ from automobiles; focus is on stability, braking, and rider protection).
Active Features
Braking System Type:
Disc brakes front and rear (e.g., 260mm front, 220mm rear), often with dual-piston calipers.
ABS Availability:
Optional or not widely available on base models for the 2003 model year; check specific market variants.
Passive Features
Lighting:
Halogen headlamp, LED taillight, turn signals.
Windscreen:
Adjustable or fixed windscreen for rider protection from elements.
💡 Technology Features
Infotainment
Instrument Cluster:
Analog speedometer, tachometer (on some variants), fuel gauge, coolant temperature indicator, warning lights.
Lighting Technology:
Standard halogen headlights, often with integrated turn signals in the fairing.
Driver Assistance
ABS Feature:
As noted, ABS was optional or unavailable on many 2003 models.
Connectivity
Connectivity Features:
N/A (No modern connectivity features like Bluetooth or USB ports are standard).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-5,000 km or annually, whichever comes first. (Consult manual for exact specification).
Air Filter Replacement:
Inspect every 5,000 km, replace as needed or every 10,000-15,000 km.
Spark Plug Replacement:
Every 8,000-12,000 km (depending on plug type, e.g., standard vs. iridium).
Cv Belt Inspection Replacement:
Inspect every 10,000 km, replace every 20,000-30,000 km or if wear is evident.
Brake Fluid Flush:
Every 2 years or as specified by fluid manufacturer.
Fluid Specifications
Engine Oil Type:
SAE 10W-40 API SG or higher (JASO MA recommended for wet clutch compatibility).
Engine Oil Capacity:
Approximately 1.1-1.3 Liters (varies by engine variant and filter change).
Coolant Type:
Ethylene glycol-based antifreeze mixture (50/50 with distilled water).
Brake Fluid Type:
DOT 4
Known Issues
Common Wear Items:
CVT belt, front fork seals, brake pads, wheel bearings, starter motor solenoid.
Engine Performance Variations:
Some older carbureted models may require periodic carburetor cleaning and adjustment for optimal running.
Electrical Gremlins:
Less common but possible: aging wiring harness connections, faulty voltage regulator.
📚 Vehicle History
Brand Heritage
Aprilia Legacy:
Aprilia has a long history in motorcycle racing and performance-oriented scooters, known for innovative engineering and sporty aesthetics.
Model Evolution
Leonardo Introduction:
The Leonardo line was Aprilia's foray into the maxi-scooter market, aiming to blend sportiness with practicality. Introduced in the late 1990s, it underwent updates and engine variants over its production life.
2003 Updates:
The 2003 model year likely features refinements to the existing platform, potentially including updated emissions compliance, minor styling tweaks, and incorporation of the Piaggio LEADER engine for the 250cc variant, which was a significant integration for Aprilia at the time.
Production
Manufacturing Location:
Italy (primarily Aprilia's Italian manufacturing facilities)
Production Period:
Late 1990s to mid-2000s, with significant model updates and engine options.
🏆 Awards & Recognition
Recognitions
Industry Awards:
While specific awards for the 2003 Leonardo might be scarce, the model was generally well-received in its segment for offering a blend of Aprilia's sporty DNA with maxi-scooter practicality.
Ratings
Owner Satisfaction:
Owners typically praised its performance, handling, and distinctive styling, particularly the 250cc variant with its Piaggio engine.
Certifications
Emission Standards:
Designed to meet prevailing emission standards for its respective market (e.g., Euro 2 in Europe).
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