2004 Aprilia Leonardo 250-300 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Aprilia Model: Leonardo Model Variant: 250-300 Year: 2004 Codes Chassis Code Prefix: AP07 Engine Code Prefix: VG11 👋 Introduction Market Position Segment: Maxi-scooter, urban commuter,...

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Type: Motorcycle

Vendor:

Sku: 602398

Tags: 2004 Aprilia Featured Leonardo Leonardo 250 Leonardo 300 Motorcycle Motorcycles

Product variants

Description

🏷️ Basic Information

Identification

Make:

Aprilia

Model:

Leonardo

Model Variant:

250-300

Year:

Codes

Chassis Code Prefix:

Engine Code Prefix:

👋 Introduction

Market Position

Segment:

Maxi-scooter, urban commuter, light touring.

Target Audience:

Commuters seeking a balance of performance, comfort, and practicality; riders looking for a capable step-up from smaller scooters.

Competitive Analysis

Competitors 2004:

Honda Pantheon 150/250, Yamaha Majesty 250, Suzuki Burgman 250, Piaggio X9 250.

Key Features

Design Philosophy:

Sporty yet comfortable maxi-scooter design, offering good weather protection and underseat storage.

Engine Type:

Liquid-cooled, four-stroke single-cylinder engine.

📋 Manual Details

Coverage Areas

Primary Coverage:

Workshop Service and Repair

Model Years Covered:

Specifically for 2004 models, but likely covers a broader range of Leonardo 250 and 300 variations within the early 2000s.

Page Count

Estimated Page Count:

300-450 pages (typical for comprehensive workshop manuals of this era)

Manual Type

Type:

Workshop Service Repair Manual

Language

Language:

English (default for most international releases, confirm with seller)

Format

Format:

Digital (PDF - likely scanned from original print)

📖 Manual Coverage

Systems Covered

Engine:

Complete engine overhaul, disassembly, inspection, assembly, tuning, fuel system (carburetor settings), ignition system.

Transmission:

Automatic transmission (CVT) maintenance, belt inspection/replacement, clutch operation, variator servicing.

Brakes:

Front and rear brake system diagnosis, repair, bleeding procedures, component replacement (pads, calipers, lines, master cylinder).

Electrical:

Complete electrical system schematics, starter system, charging system (stator, regulator/rectifier), lighting, battery, fuses, wiring harness repair.

Suspension:

Front fork overhaul, rear shock absorber inspection and replacement, linkage maintenance.

Cooling System:

Radiator, fan, coolant hoses, thermostat, coolant specifications, bleeding.

Fuel System:

Fuel tank, fuel lines, carburetor servicing and tuning (Mikuni or similar), fuel filter replacement.

Exhaust System:

Exhaust pipe and muffler inspection, gasket replacement.

Bodywork:

Fairing removal and installation, seat, storage compartments, body panel repair and alignment.

Wheels And Tires:

Wheel bearing inspection and replacement, tire pressure, tire replacement procedures, wheel balancing.

Controls:

Handlebar, throttle, brake levers, cables adjustment and replacement.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, spark plug checks, chain/belt adjustments (if applicable), general lubrication.

Troubleshooting:

Diagnostic charts, common problem identification and solutions.

Repair:

Step-by-step repair instructions for all major mechanical and electrical components.

Disassembly Assembly:

Detailed procedures for complete teardown and reassembly of major vehicle systems.

Diagnostic Tests:

Procedures for checking engine compression, electrical system voltage, and component functionality.

Torque Specifications:

Precise torque values for all critical fasteners.

Technical Depth

Depth:

Comprehensive: Covers everything from basic scheduled maintenance to complete engine and transmission rebuilds. Suitable for professional technicians and experienced DIY enthusiasts.

📊 Manual Specifications

File Format

Format:

Searchable Text:

Likely searchable if OCR was performed on the scan, but not guaranteed. Basic PDF viewer compatibility.

Print Quality:

Variable: Depends on the quality of the original scan. Images and diagrams may be black and white.

Print Quality

Resolution:

Typically 300 DPI for adequate detail if well-scanned.

Binding Type

Binding:

N/A (Digital format)

Paper Type

Paper Type:

N/A (Digital format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Single-cylinder, four-stroke, OHC, liquid-cooled

Displacement Cc 250:

244.1 cc (for the 250 model)

Displacement Cc 300:

278 cc (for the 300 model, often based on the Piaggio Quasar engine family)

Bore X Stroke 250:

Approx. 72.0 mm x 60.0 mm (250)

Bore X Stroke 300:

Approx. 75.0 mm x 63.0 mm (300)

Compression Ratio:

Approx. 10.5:1 - 11.0:1 (varies slightly between 250/300)

Performance

Horsepower 250:

Approx. 21-23 HP @ 7500 RPM (250)

Horsepower 300:

Approx. 24-27 HP @ 7500 RPM (300)

Torque 250:

Approx. 21-23 Nm @ 6000 RPM (250)

Torque 300:

Approx. 24-27 Nm @ 6000 RPM (300)

Fuel System

Fuel Delivery:

Carburetor (likely Mikuni VM26 or similar for 250, potentially Keihin for 300, or EFI on later versions if applicable)

Fuel Type:

Unleaded Gasoline 95 RON (Octane rating)

Fuel Tank Capacity:

Approx. 13 liters (including reserve)

Lubrication

Engine Oil Type:

SAE 10W-40, API SG or higher (confirm with specific Aprilia recommendation)

Engine Oil Capacity Ml:

Approx. 1.3 - 1.5 liters (with oil filter change)

🔧 Transmission

Standard

Type:

Automatic Continuously Variable Transmission (CVT)

Drive Type:

Belt drive to rear wheel

Features

Variator Operation:

Automatic variator for gear ratio changes based on engine RPM and load.

Clutch Type:

Automatic centrifugal clutch

Fluid Specifications

Gear Oil Type:

Typically SAE 80W-90 hypoid gear oil for the final drive (confirm with manual)

📐 Dimensions

Exterior

Length Mm:

Approx. 2150 mm

Width Mm:

Approx. 770 mm

Height Mm:

Approx. 1400 mm (to top of screen)

Wheelbase Mm:

Approx. 1500 mm

Weights

Dry Weight Kg:

Approx. 170-180 kg (dry, depending on model)

Wet Weight Kg:

Approx. 185-195 kg (wet)

Cargo

Underseat Storage:

Sufficient for one full-face helmet and some small items.

Wheels And Tires

Front Tire Size:

120/70-14

Rear Tire Size:

140/60-13

Front Wheel Size:

14-inch

Rear Wheel Size:

13-inch

Bolt Pattern:

Typically 4-bolt for both front and rear wheels.

🛡️ Safety Features

Ratings

Safety Standards:

CE marking, compliant with European safety standards for motorcycles.

Active Features

Braking System:

Front: Disc brake (often 260mm) with dual-piston caliper. Rear: Disc brake (often 240mm) with dual-piston caliper.

Parking Brake:

Mechanical parking brake on rear caliper (common feature).

Passive Features

Lighting:

Halogen headlight, taillight, brake light, front and rear turn signals.

Instrumentation:

Speedometer, tachometer, fuel gauge, coolant temperature gauge, indicator lights.

💡 Technology Features

Infotainment

Dashboard:

Analog speedometer and tachometer, with digital elements for fuel level, odometer, trip meter, and indicator lights. Usually includes a clock.

Driver Assistance

ABS was not a standard feature on most 2004 models, though optional on some higher-spec variants or later models.

Connectivity

Connectivity Features:

None (standard for scooters of this era, no Bluetooth or smartphone integration).

🔧 Maintenance

Service Intervals

Oil Change Interval Km:

Every 5,000 km or annually, whichever comes first.

Oil Filter Change Interval Km:

Every 10,000 km or every second oil change.

Air Filter Cleaning Interval Km:

Every 5,000 km, replace as needed.

Spark Plug Replacement Interval Km:

Every 10,000 km or inspect annually.

Cv Belt Inspection Interval Km:

Every 10,000 km for inspection, replacement typically around 20,000 - 30,000 km or when wear is evident.

Brake Fluid Change Interval Years:

Every 2 years, regardless of mileage.

Fluid Specifications

Coolant Type:

Ethylene glycol based, anti-freeze/anti-corrosion coolant. (e.g., Aprilia Coolant or equivalent)

Coolant Capacity Liters:

Approx. 1.5 - 1.7 liters (including expansion tank)

Known Issues

Common Wear Items:

CVT belt wear, front fork seals, brake pads, rear suspension bushings, carburetor tuning stability.

Electrical Concerns:

Age-related degradation of wiring insulation, faulty regulator/rectifier, starter motor solenoid issues can occur.

Cooling System Issues:

Potential for thermostat sticking, fan motor failure, or radiator blockage if coolant is not maintained.

Carburetor Performance:

Can become clogged over time due to fuel varnish, requiring thorough cleaning and re-jetting.

📚 Vehicle History

Brand Heritage

Manufacturer:

Aprilia is an Italian manufacturer known for its performance-oriented motorcycles and scooters, often with a racing heritage.

Model Evolution

Leonardo Lineage:

The Leonardo line was Aprilia's entry into the maxi-scooter market, designed for comfort and touring. The 250 and 300 models represented an increase in engine capacity for enhanced performance.

Engine Source 300:

The 300cc variant of the Leonardo likely utilized a Piaggio-derived engine, as Aprilia was part of the Piaggio Group during this period, leveraging shared technology for larger displacement models.

Production

Production Period:

The Leonardo was produced from the late 1990s through the mid-2000s, with the 250 and 300 variants being prominent in the earlier part of this decade.

Manufacturing Location:

Primarily manufactured in Italy.

🏆 Awards & Recognition

Recognitions

Industry Awards:

While specific awards for the 2004 Leonardo are not widely documented, the model was generally well-received for its comfortable ride and sporty styling in the maxi-scooter segment.

Ratings

Review Sentiment:

Positive reviews often highlighted its agile handling for its size, good acceleration, and comfortable seating for longer rides.