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1997 APRILIA LEONARDO 125 Service Repair Manual

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🏷️ Basic Information Identification Make: Aprilia Model: Leonardo Year: 1997 Variant: 125 Codes Engine Code: Rotax 125cc (likely 2-stroke, liquid-cooled, single-cylinder) 👋 Introduction Market Position Market Segment: Lightweight scooter, popular for urban commuting and short-distance travel. Competitive Analysis Competitors: Competed with other 125cc scooters from brands like Piaggio (Zip, Liberty), Yamaha (Jog, Axis), Honda (Dio, Lead). Key Features Design: Sporty styling, comfortable seating, under-seat storage, agile handling. Engine Type: Performance-oriented 2-stroke engine, known for its punchy acceleration. 📋 Manual Details Coverage Areas Systems Covered: Engine, Transmission, Fuel System, Ignition System, Cooling System, Electrical System, Chassis, Suspension, Brakes, Bodywork, Troubleshooting, Maintenance Page Count Page Count: Likely 200-300 pages (typical for a comprehensive service manual of this era) Manual Type Manual Type: Service Repair Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Complete disassembly and reassembly of the 125cc Rotax engine, including cylinder, piston, crankshaft, connecting rod, bearings, seals, and gaskets. Fuel System: Carburetor adjustment and overhaul (likely Dell'Orto or similar), fuel lines, fuel pump, fuel filter. Ignition System: CDI ignition system, spark plug specifications, ignition timing, troubleshooting ignition faults. Cooling System: Radiator, coolant flow, water pump, thermostat, fan operation, coolant specifications, bleeding procedures. Transmission Drivetrain: Automatic transmission (likely CVT - Continuously Variable Transmission), clutch operation, variator, torque converter, drive belt inspection and replacement, final drive. Electrical System: Wiring diagrams, battery specifications, charging system (alternator/stator), starter motor, lighting, horn, switches, fuses, troubleshooting electrical circuits. Chassis Frame: Frame inspection, welding points, steering head bearings, center stand, side stand. Suspension Front: Front fork overhaul, oil specifications, seal replacement, spring rates, damping adjustments. Suspension Rear: Rear shock absorber specifications, adjustment, linkage lubrication, swingarm bearings. Brakes Front: Front brake caliper service, brake pad replacement, master cylinder overhaul, brake fluid specifications (DOT 4), bleeding procedures, rotor specifications. Brakes Rear: Rear brake caliper service, brake pad replacement, master cylinder overhaul, brake fluid specifications (DOT 4), bleeding procedures, rotor specifications. Wheels Tires: Wheel bearing inspection and replacement, tire pressure specifications, recommended tire sizes. Bodywork Fairings: Panel removal and installation, fairing repair, seat removal, storage compartment access. Procedures Included Routine Maintenance: Oil change intervals and specifications, air filter cleaning/replacement, spark plug replacement, chain/belt adjustment, brake adjustments. Engine Rebuild: Detailed step-by-step instructions for full engine disassembly, inspection, component replacement (piston, rings, bearings, seals), and reassembly with torque specifications. Carburetor Overhaul: Complete carburetor disassembly, cleaning, reassembly, jetting adjustments, and idle speed settings. Brake System Service: Bleeding the brake system, replacing brake pads and rotors, servicing brake calipers and master cylinders. Suspension Fork Rebuild: Front fork oil change, seal replacement, and general overhaul procedures. Electrical Troubleshooting: Diagnosis of common electrical issues using wiring diagrams and multimeter testing. Troubleshooting Guides: Diagnostic flowcharts and symptom-based troubleshooting for various mechanical and electrical problems. Technical Depth Depth Level: Comprehensive, covering everything from basic maintenance to full engine and transmission rebuilds, including advanced diagnostics. 📊 Manual Specifications File Format File Format: PDF Print Quality Print Quality: High-resolution scans of original manual pages, ensuring clarity of text and diagrams. Binding Type Binding Type: N/A (Digital Format) Paper Type Paper Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Type: 2-stroke, liquid-cooled, single-cylinder, Rotax Displacement: 124.8 cc (125cc class) Bore X Stroke: Approximately 54 mm x 54.5 mm (typical for this engine) - specific data may vary, check manual. Compression Ratio: Likely around 7.0:1 to 8.0:1 (for 2-stroke) - specific data in manual. Performance Horsepower Output: Approx. 14-15 HP at 7,500-8,500 RPM (estimated, performance tuning can vary) Torque Output: Approx. 1.3-1.4 kgf-m at 7,000-7,500 RPM (estimated) Fuel System Carburetor Model: Likely Dell'Orto PHVB 26 or similar Fuel Delivery: Carburetor Fuel Type: Unleaded gasoline (RON 95 or higher recommended) Oil Mixing: Automatic oil injection system Lubrication Engine Oil Type: 2-stroke specific engine oil (e.g., Motul 510, Castrol Power 1 TTS) - specific viscosity (e.g., SAE 7.5W-30) and API rating (e.g., API TC, JASO FD) in manual. Transmission Oil Type: Gear oil (e.g., SAE 80W-90) - specific capacity and API GL-4 rating in manual. 🔧 Transmission Standard Transmission Type: Automatic (CVT - Continuously Variable Transmission) Optional Optional Transmissions: N/A (CVT was standard for this model) Features Clutch Type: Centrifugal automatic clutch Drive Belt: V-belt drive system Final Drive: Gear reduction drive 📐 Dimensions Exterior Length: Approx. 1900-2000 mm (estimate, specific dimensions in manual) Width: Approx. 700-750 mm (estimate, specific dimensions in manual) Height: Approx. 1200-1250 mm (estimate, specific dimensions in manual) Wheelbase: Approx. 1350-1380 mm (estimate, specific dimensions in manual) Weights Dry Weight: Approx. 120-130 kg (estimate, specific weight in manual) Fuel Tank Capacity: Approx. 8-10 liters (estimate, specific capacity in manual) 🛡️ Safety Features Ratings Safety Ratings: Not applicable for this vehicle category in the same way as cars; focus on build quality and braking performance. Active Features Braking System: Disc brakes front and rear, providing effective stopping power. Handling: Agile chassis and...
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1997 APRILIA LEONARDO 125 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
Leonardo
Year:
1997
Variant:
125
Codes
Engine Code:
Rotax 125cc (likely 2-stroke, liquid-cooled, single-cylinder)
👋 Introduction
Market Position
Market Segment:
Lightweight scooter, popular for urban commuting and short-distance travel.
Competitive Analysis
Competitors:
Competed with other 125cc scooters from brands like Piaggio (Zip, Liberty), Yamaha (Jog, Axis), Honda (Dio, Lead).
Key Features
Design:
Sporty styling, comfortable seating, under-seat storage, agile handling.
Engine Type:
Performance-oriented 2-stroke engine, known for its punchy acceleration.
📋 Manual Details
Coverage Areas
Systems Covered:
Engine, Transmission, Fuel System, Ignition System, Cooling System, Electrical System, Chassis, Suspension, Brakes, Bodywork, Troubleshooting, Maintenance
Page Count
Page Count:
Likely 200-300 pages (typical for a comprehensive service manual of this era)
Manual Type
Manual Type:
Service Repair Manual
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete disassembly and reassembly of the 125cc Rotax engine, including cylinder, piston, crankshaft, connecting rod, bearings, seals, and gaskets.
Fuel System:
Carburetor adjustment and overhaul (likely Dell'Orto or similar), fuel lines, fuel pump, fuel filter.
Ignition System:
CDI ignition system, spark plug specifications, ignition timing, troubleshooting ignition faults.
Cooling System:
Radiator, coolant flow, water pump, thermostat, fan operation, coolant specifications, bleeding procedures.
Transmission Drivetrain:
Automatic transmission (likely CVT - Continuously Variable Transmission), clutch operation, variator, torque converter, drive belt inspection and replacement, final drive.
Electrical System:
Wiring diagrams, battery specifications, charging system (alternator/stator), starter motor, lighting, horn, switches, fuses, troubleshooting electrical circuits.
Chassis Frame:
Frame inspection, welding points, steering head bearings, center stand, side stand.
Suspension Front:
Front fork overhaul, oil specifications, seal replacement, spring rates, damping adjustments.
Suspension Rear:
Rear shock absorber specifications, adjustment, linkage lubrication, swingarm bearings.
Brakes Front:
Front brake caliper service, brake pad replacement, master cylinder overhaul, brake fluid specifications (DOT 4), bleeding procedures, rotor specifications.
Brakes Rear:
Rear brake caliper service, brake pad replacement, master cylinder overhaul, brake fluid specifications (DOT 4), bleeding procedures, rotor specifications.
Wheels Tires:
Wheel bearing inspection and replacement, tire pressure specifications, recommended tire sizes.
Bodywork Fairings:
Panel removal and installation, fairing repair, seat removal, storage compartment access.
Procedures Included
Routine Maintenance:
Oil change intervals and specifications, air filter cleaning/replacement, spark plug replacement, chain/belt adjustment, brake adjustments.
Engine Rebuild:
Detailed step-by-step instructions for full engine disassembly, inspection, component replacement (piston, rings, bearings, seals), and reassembly with torque specifications.
Carburetor Overhaul:
Complete carburetor disassembly, cleaning, reassembly, jetting adjustments, and idle speed settings.
Brake System Service:
Bleeding the brake system, replacing brake pads and rotors, servicing brake calipers and master cylinders.
Suspension Fork Rebuild:
Front fork oil change, seal replacement, and general overhaul procedures.
Electrical Troubleshooting:
Diagnosis of common electrical issues using wiring diagrams and multimeter testing.
Troubleshooting Guides:
Diagnostic flowcharts and symptom-based troubleshooting for various mechanical and electrical problems.
Technical Depth
Depth Level:
Comprehensive, covering everything from basic maintenance to full engine and transmission rebuilds, including advanced diagnostics.
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Print Quality:
High-resolution scans of original manual pages, ensuring clarity of text and diagrams.
Binding Type
Binding Type:
N/A (Digital Format)
Paper Type
Paper Type:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
2-stroke, liquid-cooled, single-cylinder, Rotax
Displacement:
124.8 cc (125cc class)
Bore X Stroke:
Approximately 54 mm x 54.5 mm (typical for this engine) - specific data may vary, check manual.
Compression Ratio:
Likely around 7.0:1 to 8.0:1 (for 2-stroke) - specific data in manual.
Performance
Horsepower Output:
Approx. 14-15 HP at 7,500-8,500 RPM (estimated, performance tuning can vary)
Torque Output:
Approx. 1.3-1.4 kgf-m at 7,000-7,500 RPM (estimated)
Fuel System
Carburetor Model:
Likely Dell'Orto PHVB 26 or similar
Fuel Delivery:
Carburetor
Fuel Type:
Unleaded gasoline (RON 95 or higher recommended)
Oil Mixing:
Automatic oil injection system
Lubrication
Engine Oil Type:
2-stroke specific engine oil (e.g., Motul 510, Castrol Power 1 TTS) - specific viscosity (e.g., SAE 7.5W-30) and API rating (e.g., API TC, JASO FD) in manual.
Transmission Oil Type:
Gear oil (e.g., SAE 80W-90) - specific capacity and API GL-4 rating in manual.
🔧 Transmission
Standard
Transmission Type:
Automatic (CVT - Continuously Variable Transmission)
Optional
Optional Transmissions:
N/A (CVT was standard for this model)
Features
Clutch Type:
Centrifugal automatic clutch
Drive Belt:
V-belt drive system
Final Drive:
Gear reduction drive
📐 Dimensions
Exterior
Length:
Approx. 1900-2000 mm (estimate, specific dimensions in manual)
Width:
Approx. 700-750 mm (estimate, specific dimensions in manual)
Height:
Approx. 1200-1250 mm (estimate, specific dimensions in manual)
Wheelbase:
Approx. 1350-1380 mm (estimate, specific dimensions in manual)
Weights
Dry Weight:
Approx. 120-130 kg (estimate, specific weight in manual)
Fuel Tank Capacity:
Approx. 8-10 liters (estimate, specific capacity in manual)
🛡️ Safety Features
Ratings
Safety Ratings:
Not applicable for this vehicle category in the same way as cars; focus on build quality and braking performance.
Active Features
Braking System:
Disc brakes front and rear, providing effective stopping power.
Handling:
Agile chassis and suspension designed for maneuverability in urban environments.
Passive Features
Lighting:
Headlight, taillight, brake lights, turn signals for visibility.
Mirrors:
Rearview mirrors for situational awareness.
💡 Technology Features
Infotainment
Infotainment System:
Basic analog instrument cluster: speedometer, odometer, fuel gauge, indicator lights.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 3,000-4,000 km or annually. Specific interval in manual.
Air Filter Cleaning:
Every 2,000-3,000 km or as needed based on operating conditions. Replacement recommended every 6,000-8,000 km.
Spark Plug Replacement:
Every 5,000-6,000 km. Specific plug type (e.g., NGK CR7E or similar) in manual.
Drive Belt Inspection:
Inspect every 5,000 km, replace as needed (typically around 10,000-15,000 km depending on usage).
Brake Fluid Flush:
Every 2 years or as per manual recommendation. Use DOT 4 brake fluid.
Fluid Specifications
Coolant Type:
Ethylene glycol-based coolant with anti-corrosion additives. Mixing ratio 50/50 with distilled water recommended. Specific brand/type in manual.
Known Issues
Common Problems:
Wear on CVT components (variator rollers, clutch shoes), carburetor tuning issues, potential for 2-stroke engine wear if not maintained properly, electrical connections can corrode.
📚 Vehicle History
Brand Heritage
Manufacturer Origin:
Aprilia is an Italian manufacturer with a strong heritage in motorcycle and scooter racing and production.
Model Evolution
Leonardo Lineup:
The Leonardo was Aprilia's entry into the modern maxi-scooter market, offering a blend of sportiness and practicality. It was produced in various engine displacements (50cc, 125cc, 150cc, 250cc).
Production
Production Years:
The Leonardo series was produced from the mid-1990s into the early 2000s, with the 125cc model being a prominent offering in the initial years.
Manufacturing Location:
Italy
🏆 Awards & Recognition
Recognitions
Industry Awards:
While specific awards for the 1997 Leonardo 125 are not widely documented, the model was well-regarded for its sporty design and performance within its class.
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