APRILIA HABANA MOJITO 50 125 150 1999-2012 Service Repair Manual
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🏷️ Basic Information Identification Make: Aprilia Model: Habana / Mojito Engine Options: 50cc, 125cc, 150cc Production Years Covered: 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010, 2011, 2012 Codes Product Code Designation: Service Repair Manual 👋 Introduction Market Position Scooter Segment: Lightweight urban mobility scooter, retro styling Target Audience: Commuters, younger riders, enthusiasts of vintage-styled scooters Competitive Analysis Key Competitors Era: Vespa LX series, Piaggio Zip, Kymco Agility, Yamaha Neo's Key Features Design Heritage: Retro, classic styling inspired by 1950s scooters (Habana) and more modern, rounded aesthetics (Mojito). Engine Options Appeal: Offers a range from economical 50cc for city use to more powerful 125/150cc for increased performance and highway capability. Manual Value Proposition: Provides professional-level repair and maintenance information, crucial for owners and independent repair shops to maintain these Italian scooters. 📋 Manual Details Coverage Areas Primary Coverage: Aprilia Habana and Mojito scooters Engine Variants Covered: 50cc (2-stroke, Piaggio/Rotax engines), 125cc (4-stroke, Piaggio LEADER engine), 150cc (4-stroke, Piaggio LEADER engine) Page Count Estimated Page Count: Approximately 300-400 pages (typical for comprehensive manuals of this era) Manual Type Type: Official Full Service Repair Manual Language Language: English (presumed based on typical aftermarket documentation) Format Format: Digital (likely PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine disassembly, assembly, inspection, torque specifications, component identification, cylinder, piston, crankshaft, camshaft (if applicable), valve timing, lubrication system, cooling system (air-cooled for 50cc, liquid-cooled for 125/150cc). Engine Fuel And Ignition: Carburetor systems (Dell'Orto/Mikuni), fuel injection (if applicable on later models), ignition system components (CDI, stator, spark plug), emissions control systems, starter system, charging system (alternator, battery). Transmission And Drivetrain: Automatic Continuously Variable Transmission (CVT) system, clutch operation, variator, torque converter, drive belt, final drive (gearbox), fluid specifications and replacement. Brakes: Front and rear brake systems (disc/drum configurations), hydraulic systems, brake fluid type and bleeding procedures, caliper and master cylinder overhauls, pad and shoe replacement, linkage adjustments. Suspension: Front telescopic forks, rear shock absorber(s), fork seal replacement, fluid change, spring and damper specifications, preload adjustment (if applicable). Electrical System: Wiring diagrams, lighting systems (headlight, taillight, turn signals), battery maintenance, fuse box layout, starter motor circuit, charging system diagnostics, horn, switches, instrument panel functionality, troubleshooting electrical faults. Chassis And Bodywork: Frame structure, body panel removal and installation, seat, handlebars, footpegs, storage compartment, fairings, plastics, trim components, center stand, side stand. Procedures Included Routine Maintenance: Oil changes, filter replacements (air, oil, fuel), spark plug checks and replacement, brake adjustments, tire pressure checks, chain/belt tension (if applicable), general lubrication. Troubleshooting Guides: Diagnostic flowcharts for common problems (e.g., no-start, poor running, electrical issues), symptom-based troubleshooting, fault code interpretation (if applicable). Repair Procedures: Step-by-step instructions for component removal, overhaul, and reinstallation for all major systems, including detailed diagrams and torque values. Assembly And Disassembly: Complete breakdown and reassembly guides for the entire scooter, facilitating major repairs or restorations. Technical Depth Diagnostic Capabilities: Advanced diagnostics for engine performance, electrical systems, and fuel delivery, enabling professional-level troubleshooting. Rebuild Information: Comprehensive information for complete engine rebuilds, including precision measurements and tolerances for internal components. Specification Data: Detailed technical specifications, tolerances, clearances, torque values, fluid capacities, and electrical data for all components. 📊 Manual Specifications File Format Digital Format: PDF (Portable Document Format) Print Quality Image Resolution: High-resolution images and diagrams for clarity. Text Searchability: Searchable text for quick information retrieval. Binding Type Binding: N/A (Digital Format) Paper Type Paper Quality: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine 50Cc Type: 2-stroke, single-cylinder Cooling: Forced Air Cooling Displacement: Approx. 49.4 cc Primary Engine 125Cc Type: 4-stroke, single-cylinder, SOHC Cooling: Liquid Cooling Displacement: Approx. 124 cc Primary Engine 150Cc Type: 4-stroke, single-cylinder, SOHC Cooling: Liquid Cooling Displacement: Approx. 150 cc Performance 125Cc Horsepower: Approx. 10-12 HP (varies by year and specific engine tune) Torque: Approx. 9-10 Nm (varies by year and specific engine tune) Fuel System 50Cc System: Carburetor (e.g., Dell'Orto PHVA 12/14 or similar) Fuel System 125 150Cc System: Carburetor (e.g., Dell'Orto PHVA 20/26 or similar) or possibly early EFI on some later models (manual would clarify). Fuel Type Required Fuel: Unleaded gasoline (Octane rating typically 95 RON / 91 AKI recommended). Lubrication Oil Type 50Cc: 2-stroke engine oil, meeting API TC or JASO FD specifications. Oil Type 125 150Cc: 4-stroke motorcycle engine oil, SAE 10W-40, API SG/SH/SJ or higher, JASO MA recommended. 🔧 Transmission Standard Type: Automatic CVT (Continuously Variable Transmission) Optional Gearbox Type: N/A (All models utilize automatic CVT) Features Drive System: V-belt drive to rear wheel via reduction gears. Transmission Fluid: Gear oil for final drive reduction, typically SAE 80W-90 API GL-4. 📐 Dimensions Exterior Habana Length: Approx. 1,840 mm Width: Approx. 750 mm (at handlebars) Seat Height: Approx. 780 mm Exterior Mojito Length: Approx. 1,900 mm Width: Approx. 730 mm (at handlebars) Seat Height: Approx. 770 mm Weights Dry Weight 50Cc: Approx. 95-105 kg Dry Weight 125Cc: Approx....
Approximately 300-400 pages (typical for comprehensive manuals of this era)
Manual Type
Type:
Official Full Service Repair Manual
Language
Language:
English (presumed based on typical aftermarket documentation)
Format
Format:
Digital (likely PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine disassembly, assembly, inspection, torque specifications, component identification, cylinder, piston, crankshaft, camshaft (if applicable), valve timing, lubrication system, cooling system (air-cooled for 50cc, liquid-cooled for 125/150cc).
Engine Fuel And Ignition:
Carburetor systems (Dell'Orto/Mikuni), fuel injection (if applicable on later models), ignition system components (CDI, stator, spark plug), emissions control systems, starter system, charging system (alternator, battery).
Transmission And Drivetrain:
Automatic Continuously Variable Transmission (CVT) system, clutch operation, variator, torque converter, drive belt, final drive (gearbox), fluid specifications and replacement.
Brakes:
Front and rear brake systems (disc/drum configurations), hydraulic systems, brake fluid type and bleeding procedures, caliper and master cylinder overhauls, pad and shoe replacement, linkage adjustments.
Suspension:
Front telescopic forks, rear shock absorber(s), fork seal replacement, fluid change, spring and damper specifications, preload adjustment (if applicable).
Electrical System:
Wiring diagrams, lighting systems (headlight, taillight, turn signals), battery maintenance, fuse box layout, starter motor circuit, charging system diagnostics, horn, switches, instrument panel functionality, troubleshooting electrical faults.
Chassis And Bodywork:
Frame structure, body panel removal and installation, seat, handlebars, footpegs, storage compartment, fairings, plastics, trim components, center stand, side stand.
Gear oil for final drive reduction, typically SAE 80W-90 API GL-4.
📐 Dimensions
Exterior Habana
Length:
Approx. 1,840 mm
Width:
Approx. 750 mm (at handlebars)
Seat Height:
Approx. 780 mm
Exterior Mojito
Length:
Approx. 1,900 mm
Width:
Approx. 730 mm (at handlebars)
Seat Height:
Approx. 770 mm
Weights
Dry Weight 50Cc:
Approx. 95-105 kg
Dry Weight 125Cc:
Approx. 120-130 kg
Curb Weight 150Cc:
Approx. 125-135 kg
Fuel Tank Capacity:
Approx. 7-8 Liters
Wheels And Tires
Front Tire Size Habana:
3.00-10
Rear Tire Size Habana:
3.50-10
Front Tire Size Mojito:
110/70-13
Rear Tire Size Mojito:
130/60-13
Wheel Bolt Pattern:
N/A (Scooter specific hub mounting)
🛡️ Safety Features
Ratings
Crash Test Data:
Not typically subjected to formal automotive crash tests; focus on rider safety through design and braking.
Active Features
Braking System:
Front disc brake, rear drum or disc brake depending on model/variant. ABS was not common in this segment during these years.
Lighting:
Halogen headlight, LED taillight/brake light (on some models), front and rear turn signals.
Passive Features
Frame Construction:
Steel tube frame providing structural integrity.
Seat Belt:
N/A (Motorcycle/scooter)
Airbags:
N/A (Motorcycle/scooter)
💡 Technology Features
Infotainment
Instrument Cluster:
Analog speedometer, fuel gauge, turn signal indicators, high beam indicator, warning lights (e.g., oil, engine, battery). Some may have basic digital elements.
Driver Assistance
ABS Availability:
ABS was not a standard or common option on these models from 1999-2012.
Connectivity
Bluetooth Or Usb:
N/A (Not featured on these models).
🔧 Maintenance
Service Intervals Oil 50Cc
Engine Oil Change:
Every 3,000 - 5,000 km or annually (check manual for specific recommendations).
Service Intervals Oil 125 150Cc
Engine Oil Change:
Every 5,000 - 7,000 km or annually (check manual for specific recommendations).
Service Intervals Filters
Air Filter Replacement:
Every 6,000 - 10,000 km or as needed based on operating conditions.
Fuel Filter Replacement:
Every 10,000 - 15,000 km or if fuel delivery issues arise.
Service Intervals Belt Clutch
Cvt Drive Belt Inspection:
Every 6,000 - 10,000 km for wear and cracks.
Cvt Drive Belt Replacement:
Typically every 12,000 - 20,000 km, depending on usage and wear.
Fluid Specifications
Brake Fluid Type:
DOT 4 or DOT 3 (confirm in manual), should be replaced every 2 years.
Coolant Type 125 150Cc:
Ethylene glycol-based coolant with corrosion inhibitors. Typically a 50/50 mix with distilled water.
Known Issues
Electrical Connections:
Corrosion or loose connections in wiring harness, especially in exposed areas, leading to intermittent faults.
Carburetor Issues 50Cc:
Jetting can become clogged over time, leading to poor running, especially with modern fuel formulations. Diaphragm failures in older carburetors.
Cvt Wear:
Drive belt can stretch or fray, variator rollers can wear unevenly, leading to sluggish acceleration or belt slippage.
Fuel System Reliability:
Fuel pumps (on EFI models) or carburetor float needles can fail. Fuel lines can degrade.
Suspension Leaks:
Front fork seals can develop leaks over time, requiring replacement.
Cooling System Leaks 125 150Cc:
Hoses and seals in the liquid cooling system can degrade, leading to coolant leaks.
📚 Vehicle History
Brand Heritage
Aprilia Legacy:
Aprilia is an Italian manufacturer with a rich history in motorcycle racing (Grand Prix) and performance scooters, known for its sporty DNA and innovative design.
Model Evolution
Habana Introduction:
Launched in the late 1990s, the Habana (also known as Mojito Custom in some markets) was designed to evoke a classic, retro aesthetic, competing with similarly styled scooters from Vespa.
Mojito Introduction:
The Mojito evolved from the Habana concept, often featuring slightly different styling cues, particularly in the headlight and bodywork, and introduced larger wheel options on some versions.
Engine Adoption:
Initially, the Habana/Mojito used Piaggio's 50cc 2-stroke engines (often derived from Rotax or Piaggio's own units), later adopting Piaggio's reliable 4-stroke LEADER engines for 125cc and 150cc variants.
Production
Manufacturing Location:
Primarily Italy, by Aprilia S.p.A.
🏆 Awards & Recognition
Recognitions
Design Awards:
The retro styling of the Habana/Mojito often garnered praise for its aesthetic appeal, contributing to its marketability among style-conscious buyers.
Ratings
Reliability Ratings:
Generally considered reliable when properly maintained, with Piaggio engines being robust. Specific reliability varies with model year and individual maintenance history.
Certifications
Emissions Standards:
Models produced within the specified years would conform to the respective European (Euro 1, 2, 3) or regional emissions standards applicable at the time of manufacture.