Aprilia Habana Mojito 50 2004 Factory Service Repair Manual
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🏷️ Basic Information Identification Make: Aprilia Model: Habana Mojito 50 Year: 2004 Codes Chassis Code: AP82300A Engine Code Family: Piaggio Hi-PER 2 👋 Introduction Market Position Segment: Lightweight scooter (50cc class), urban mobility, retro styling. Competitive Analysis Competitors 2004: Honda Dio, Yamaha Jog, Vespa ET2, SYM Fiddle, Kymco Agility 50. Key Features Vehicle Design Philosophy: Nostalgic, stylish design inspired by classic scooters with modern performance and reliability. Key Features Manual Value Proposition: Provides comprehensive, authoritative technical information directly from the manufacturer, enabling accurate maintenance and repair, thereby extending the vehicle's lifespan and preserving its performance. 📋 Manual Details Coverage Areas Primary Focus: Service, Repair, Maintenance, Troubleshooting Secondary Focus: Diagnostics, Specifications, Wiring Diagrams Page Count Estimated Pages: Hundreds (exact count not specified, but described as 'complete' and 'hundreds of pages') Manual Type Type: Factory Service Repair Manual Language Language: English (presumed, as product listing is in English) Format Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: Engine overhaul, carburetor tuning, fuel system, ignition system, exhaust system, cooling system (air-cooled), starting system, charging system. Chassis: Frame inspection, suspension (front fork, rear shock absorber), steering system, wheels, tires, brakes (front disc, rear drum), bodywork and panels, seat assembly. Electrical: Wiring diagrams, lighting system (headlight, taillight, indicators), horn, battery, fuses, ignition switch, starter motor, instrument cluster. Procedures Included Maintenance: Oil changes, filter replacements (air, fuel, oil if applicable), spark plug service, brake adjustments, chain/belt inspection and adjustment (if applicable), general lubrication, cleaning. Repair: Engine rebuild, carburetor overhaul, suspension component replacement, brake caliper/master cylinder service, electrical component repair/replacement, body panel repair and adjustment. Troubleshooting: Diagnostic charts for common issues, symptom-based problem solving, electrical troubleshooting guides, mechanical failure analysis. Technical Depth Depth: Comprehensive factory-level repair procedures, detailed specifications, torque values, component tolerances, and diagnostic information suitable for professional technicians and experienced DIY mechanics. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable for efficient information retrieval (standard for modern PDF manuals). Print Quality Printability: Designed for printing, allowing users to print the entire manual or specific sections as needed. Binding Type Binding Type: N/A (Digital PDF, user prints and binds) Paper Type Paper Type: N/A (Digital PDF, user chooses paper type for printing) ⚙️ Engine Specifications Primary Engine Engine Type: Two-stroke, single-cylinder Displacement: 49.3 cc Bore X Stroke: 39.0 mm x 41.4 mm (typical for Piaggio Hi-PER 2 50cc) Cooling System: Forced Air Cooling Fuel Delivery: Carburetor (likely a Dell'Orto PHVA or similar 17.5mm) Ignition System: Electronic ignition (CDI) Lubrication: Automatic oil injection (separate oil tank) Performance Horsepower Peak: Approx. 4.5 - 5.0 HP @ 6500 RPM (typical for this engine in stock configuration) Torque Peak: Approx. 5.0 - 5.5 Nm @ 6000 RPM (typical) Fuel System Fuel Type: Unleaded Gasoline (95 RON recommended) Fuel Tank Capacity: Approx. 7.0 Liters Oil Tank Capacity: Approx. 1.2 Liters (2-stroke oil) 🔧 Transmission Standard Type: Automatic CVT (Continuously Variable Transmission) Drive Belt Part Number: Refer to manual for exact part number (e.g., Piaggio 837910) Clutch Type: Automatic centrifugal clutch Features Gear Reduction: Integrated final drive via gears. 📐 Dimensions Exterior Length: Approx. 1800 mm Width: Approx. 700 mm (at handlebars) Height: Approx. 1180 mm (to handlebars) Wheelbase: Approx. 1280 mm Weights Dry Weight: Approx. 92 kg Gross Vehicle Weight Rating Gvwr: Refer to manual for exact specification (typically around 250 kg including rider and cargo) Cargo Underseat Storage: Yes, significant storage capacity for helmet or groceries. 🛡️ Safety Features Ratings Crash Test Data: Not applicable for 50cc scooters of this era in typical automotive safety rating systems. Active Features Braking System: Front: Hydraulic Disc Brake; Rear: Mechanical Drum Brake. Lighting: Headlight, taillight, brake light, front and rear turn signals. Passive Features Frame Construction: Steel monocoque frame for rigidity. Handgrips: Ergonomically designed for control and comfort. 💡 Technology Features Infotainment Instrument Cluster: Analog speedometer, odometer, fuel level indicator, indicator lights (turn signals, high beam, oil warning). Driver Assistance ABS: Not equipped Connectivity Bluetooth Usb: Not equipped 🔧 Maintenance Service Intervals Engine Oil Change: Every 3,000 - 5,000 km or annually (refer to manual for precise recommendation; for 2-stroke oil injection, it relates to the oil reservoir). Air Filter Cleaning Replacement: Inspect every 3,000 km, clean or replace as needed; replace every 6,000 - 10,000 km. Spark Plug Replacement: Inspect every 3,000 km, replace every 6,000 - 9,000 km (recommended plug: NGK CR9EB or equivalent). Brake Fluid Flush: Every 2 years or as per manual specification. Fluid Specifications Engine Oil Type: Specific 2-stroke synthetic or semi-synthetic oil for automatic oil injection systems (API TC, JASO FD/FC rated). Gearbox Oil Type: SAE 80W-90 transmission oil (API GL-3 or GL-4). Brake Fluid Type: DOT 3 or DOT 4 hydraulic brake fluid. Known Issues Common Wear Items: Drive belt wear, carburetor jetting issues (clogging), spark plug fouling, suspension wear (bushings, seals), brake pad/shoe wear. Electrical Gremlins: Corrosion on electrical connectors, headlight/taillight...
Nostalgic, stylish design inspired by classic scooters with modern performance and reliability.
Key Features Manual
Value Proposition:
Provides comprehensive, authoritative technical information directly from the manufacturer, enabling accurate maintenance and repair, thereby extending the vehicle's lifespan and preserving its performance.
📋 Manual Details
Coverage Areas
Primary Focus:
Service, Repair, Maintenance, Troubleshooting
Secondary Focus:
Diagnostics, Specifications, Wiring Diagrams
Page Count
Estimated Pages:
Hundreds (exact count not specified, but described as 'complete' and 'hundreds of pages')
Manual Type
Type:
Factory Service Repair Manual
Language
Language:
English (presumed, as product listing is in English)
Oil changes, filter replacements (air, fuel, oil if applicable), spark plug service, brake adjustments, chain/belt inspection and adjustment (if applicable), general lubrication, cleaning.
Repair:
Engine rebuild, carburetor overhaul, suspension component replacement, brake caliper/master cylinder service, electrical component repair/replacement, body panel repair and adjustment.
Troubleshooting:
Diagnostic charts for common issues, symptom-based problem solving, electrical troubleshooting guides, mechanical failure analysis.
Technical Depth
Depth:
Comprehensive factory-level repair procedures, detailed specifications, torque values, component tolerances, and diagnostic information suitable for professional technicians and experienced DIY mechanics.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely text-searchable for efficient information retrieval (standard for modern PDF manuals).
Print Quality
Printability:
Designed for printing, allowing users to print the entire manual or specific sections as needed.
Binding Type
Binding Type:
N/A (Digital PDF, user prints and binds)
Paper Type
Paper Type:
N/A (Digital PDF, user chooses paper type for printing)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Two-stroke, single-cylinder
Displacement:
49.3 cc
Bore X Stroke:
39.0 mm x 41.4 mm (typical for Piaggio Hi-PER 2 50cc)
Cooling System:
Forced Air Cooling
Fuel Delivery:
Carburetor (likely a Dell'Orto PHVA or similar 17.5mm)
Ignition System:
Electronic ignition (CDI)
Lubrication:
Automatic oil injection (separate oil tank)
Performance
Horsepower Peak:
Approx. 4.5 - 5.0 HP @ 6500 RPM (typical for this engine in stock configuration)
Corrosion on electrical connectors, headlight/taillight bulb failures, battery terminal issues.
Engine Performance Loss:
Can be due to clogged air filter, worn carburetor components, incorrect fuel/oil mixture, or carbon buildup in the exhaust.
📚 Vehicle History
Brand Heritage
Aprilia Origins:
Founded in 1945 in Noale, Italy, Aprilia is renowned for its expertise in small-displacement motorcycles and scooters, with a strong racing pedigree.
Model Evolution
Habana Mojito Lineage:
The Habana Mojito series is characterized by its retro styling, directly referencing classic Italian scooters, while utilizing modern Piaggio Group engine technology.
Production
Manufacturing Location:
Primarily manufactured in Italy (Piaggio Group facilities).
Production Period 2004:
Represents a specific model year within the production run of the Habana Mojito 50, likely part of a continuous model update from the late 1990s through the mid-2000s.
🏆 Awards & Recognition
Recognitions
Awards Received:
Specific awards for the 2004 Habana Mojito 50 are not widely documented, but Aprilia scooters have historically been recognized for their design and performance in their respective classes.