2004 Aprilia Leonardo 250 300 Factory Service Repair Manual
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🏷️ Basic Information Identification Make: Aprilia Model: Leonardo 250 Model Variant: 300 Year: 2004 Codes Engine Code: Likely 158MI or similar designation for Rotax 250cc engine Chassis Code: May vary, refer to VIN for specific identification 👋 Introduction Market Position Market Segment: Maxi-scooter segment, offering a blend of performance, comfort, and practicality for urban commuting and light touring. Competitive Analysis Key Competitors: Yamaha Majesty 250, Suzuki Burgman 250, Honda Forza 250, Piaggio X9 250. Key Features Design Philosophy: Emphasized Italian styling with a powerful engine and comfortable ergonomics for its class. Target Audience: Commuters, urban riders, and those seeking a stylish and capable scooter for medium-distance travel. 📋 Manual Details Coverage Areas Coverage Scope: Comprehensive factory service and repair for the 2004 Aprilia Leonardo 250/300 Page Count Page Count: Estimated 300-500 pages (typical for factory service manuals of this era) Manual Type Manual Type: Factory Service Repair Manual Language Language: English Format Format: Likely PDF (digital) or printed manual 📖 Manual Coverage Systems Covered Engine: Engine disassembly, assembly, inspection, lubrication, cooling system, fuel system (carburetor or EFI), ignition system, exhaust system Transmission: Automatic CVT transmission operation, maintenance, and repair (belt replacement, variator, clutch) Chassis And Suspension: Frame, front fork, rear shock absorber, swingarm, steering system, wheel bearings Brakes: Front and rear brake system, hydraulic lines, calipers, master cylinders, brake pad replacement, bleeding procedure Electrical System: Battery, charging system (alternator, regulator/rectifier), starting system (starter motor), lighting, ignition coils, CDI unit, wiring diagrams, fuses Bodywork And Trim: Fairings, panels, seat, storage compartment, lighting fixtures, mirrors Cooling System: Radiator, coolant, fan, hoses, thermostat Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, spark plug replacement, chain adjustment (if applicable, though likely CVT), brake fluid changes, coolant flushes Troubleshooting: Diagnostic charts for common problems, electrical troubleshooting guides, engine performance issues Repair: Step-by-step repair instructions for all major mechanical and electrical components Disassembly And Assembly: Detailed procedures for dismantling and reassembling engine, transmission, suspension, and body components Technical Depth Depth: In-depth technical information suitable for professional mechanics and skilled DIY enthusiasts, covering diagnostics, repair, and overhaul 📊 Manual Specifications File Format File Format: PDF (if digital) - typically searchable and printable Print Quality Print Quality: High-resolution images and clear text (for printed versions) Binding Type Binding Type: Perfect bound or spiral bound (for printed versions) Paper Type Paper Type: Durable paper stock suitable for workshop environments (for printed versions) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, liquid-cooled, single-cylinder Displacement: 244 cc (for the 250 model, the '300' likely refers to a variant or marketing designation, but the core engine is the 250cc) Bore X Stroke: Typically around 70 mm x 64 mm for this engine family. Compression Ratio: Around 10.5:1 to 11.0:1 Valvetrain: SOHC, 4 valves per cylinder Performance Horsepower: Approximately 22-23 HP at around 7,500 RPM Torque: Approximately 22-23 Nm at around 6,000 RPM Fuel System Fuel Delivery: Carburetor (likely Keihin CVK32 or similar) or potentially early Fuel Injection depending on specific market variant. Fuel Type: Unleaded gasoline, minimum 91 octane (RON+MON)/2 Lubrication Oil Type: API SG or higher, SAE 10W-40 motorcycle specific oil Oil Capacity: Approx. 1.3 - 1.5 liters (including filter change) 🔧 Transmission Standard Transmission Type: Automatic Continuously Variable Transmission (CVT) Drive Type: Belt drive to rear wheel Features Gear Ratio: Variable, managed by variator and clutch Transmission Fluid: Likely requires a specific CVT oil or gear oil for the final drive. Refer to manual for exact specification. 📐 Dimensions Exterior Length: Approx. 2,170 mm Width: Approx. 790 mm Height: Approx. 1,400 mm Wheelbase: Approx. 1,550 mm Weights Dry Weight: Approx. 175 kg Curb Weight: Approx. 185-190 kg Gross Vehicle Weight Rating: Not typically specified for scooters, but implied by chassis design 🛡️ Safety Features Ratings Crash Test Results: N/A (motorcycles/scooters are not subject to car crash test ratings) Active Features Braking System: Hydraulic disc brakes front and rear. Likely features a linked braking system on some variants. Lighting: Halogen headlight, LED tail light, incandescent turn signals Passive Features Chassis Design: Steel tube frame for rigidity and stability. Tires: Tubeless tires 💡 Technology Features Infotainment Instrument Cluster: Analog speedometer and tachometer, digital odometer, fuel gauge, coolant temperature gauge, warning lights. Driver Assistance Braking Features: ABS was not a common option on this model, but advanced hydraulic disc systems provided strong stopping power. Connectivity Charging Port: May feature a 12V accessory socket for charging devices. Engine Management Ignition System: Electronic ignition (CDI) with automatic ignition timing. 🔧 Maintenance Service Intervals Engine Oil Change: Every 6,000 km or 12 months, whichever comes first. Oil Filter Replacement: Every 12,000 km or 24 months, or at every second oil change. Air Filter Cleaning Or Replacement: Inspect every 6,000 km, clean or replace as needed. Replace every 18,000 km. Spark Plug Replacement: Every 12,000 km. Cvt Belt Inspection/Replacement: Inspect every 6,000 km, replace typically between...
Likely requires a specific CVT oil or gear oil for the final drive. Refer to manual for exact specification.
📐 Dimensions
Exterior
Length:
Approx. 2,170 mm
Width:
Approx. 790 mm
Height:
Approx. 1,400 mm
Wheelbase:
Approx. 1,550 mm
Weights
Dry Weight:
Approx. 175 kg
Curb Weight:
Approx. 185-190 kg
Gross Vehicle Weight Rating:
Not typically specified for scooters, but implied by chassis design
🛡️ Safety Features
Ratings
Crash Test Results:
N/A (motorcycles/scooters are not subject to car crash test ratings)
Active Features
Braking System:
Hydraulic disc brakes front and rear. Likely features a linked braking system on some variants.
Lighting:
Halogen headlight, LED tail light, incandescent turn signals
Passive Features
Chassis Design:
Steel tube frame for rigidity and stability.
Tires:
Tubeless tires
💡 Technology Features
Infotainment
Instrument Cluster:
Analog speedometer and tachometer, digital odometer, fuel gauge, coolant temperature gauge, warning lights.
Driver Assistance
Braking Features:
ABS was not a common option on this model, but advanced hydraulic disc systems provided strong stopping power.
Connectivity
Charging Port:
May feature a 12V accessory socket for charging devices.
Engine Management
Ignition System:
Electronic ignition (CDI) with automatic ignition timing.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 6,000 km or 12 months, whichever comes first.
Oil Filter Replacement:
Every 12,000 km or 24 months, or at every second oil change.
Air Filter Cleaning Or Replacement:
Inspect every 6,000 km, clean or replace as needed. Replace every 18,000 km.
Spark Plug Replacement:
Every 12,000 km.
Cvt Belt Inspection/Replacement:
Inspect every 6,000 km, replace typically between 18,000 - 24,000 km depending on wear.
Brake Fluid Change:
Every 24 months, regardless of mileage.
Coolant Change:
Every 24,000 km or 24 months.
Fluid Specifications
Engine Oil Grade:
SAE 10W-40 API SG or higher
Coolant Type:
Ethylene glycol based antifreeze, 50/50 mix with distilled water
Brake Fluid Type:
DOT 4 hydraulic brake fluid
Final Drive Oil Type:
API GL-4 or GL-5 gear oil (refer to manual for exact viscosity, e.g., 75W-90)
Known Issues
Common Problems:
CVT belt wear, potential electrical connector corrosion in humid climates, carburetor jetting sensitivity to fuel quality, rear shock absorber degradation over time.
Preventative Maintenance Focus:
Regular CVT system inspection, clean electrical contacts, and ensuring proper cooling system maintenance.
📚 Vehicle History
Brand Heritage
Brand Origin:
Aprilia is an Italian manufacturer known for its performance motorcycles and scooters since 1945.
Model Evolution
Leonardo Lineage:
The Leonardo line was Aprilia's entry into the maxi-scooter market, aiming for a balance of sportiness and comfort.
Engine Platform:
Utilized a robust Rotax-designed engine platform common in many scooters of that displacement.
Production
Production Period:
The Leonardo 250 was produced from the late 1990s through the early 2000s, with updates like the 2004 model.
Manufacturing Location:
Primarily Italy
🏆 Awards & Recognition
Recognitions
Industry Awards:
While specific awards for the 2004 Leonardo 250 are not widely documented, Aprilia has a strong heritage in motorsports and scooter design.
Ratings
User Reviews:
Generally well-regarded for its styling, comfortable ride, and capable engine for its class, though sometimes criticized for parts availability and maintenance complexity compared to Japanese competitors.
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