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Aprilia Leonardo 125 2002 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Aprilia Model: Leonardo 125 Year: 2002 Codes Model Code: AP06 👋 Introduction Market Position Vehicle Segment: Premium 125cc Scooter (Urban Commuter) Target Audience: Riders seeking a stylish and reliable urban scooter with a sporty heritage. Competitive Analysis Key Competitors: Piaggio Beverly 125, Gilera Nexus 125, Yamaha X-Max 125, Honda Pantheon 125. Key Features Design Philosophy: Italian design flair combined with practical urban commuting features. Handling: Sport-oriented chassis and suspension tuning typical of Aprilia's motorcycle lineage. Ergonomics: Comfortable riding position for city use, ample legroom. Storage: Under-seat storage compartment for a helmet, glove box. 📋 Manual Details Coverage Areas Manual Type: Factory Service Repair Manual Language: English Format: Digital (Likely PDF) Page Count Estimated Page Count: ~200-300 Pages 📖 Manual Coverage Systems Covered Engine Mechanical: Complete engine disassembly, assembly, inspection, and overhaul procedures for the 125cc 4-stroke engine. Fuel System: Carburetor adjustment, cleaning, and overhaul; fuel pump operation and testing; fuel tank and line maintenance. Ignition System: Spark plug specifications, ignition timing, CDI unit testing, and troubleshooting. Cooling System: Radiator and fan operation, coolant specifications and replacement, water pump inspection and repair. Transmission System: CVT (Continuously Variable Transmission) component inspection, belt replacement, clutch and variator servicing. Brakes System: Front and rear brake caliper service, master cylinder overhaul, brake fluid replacement, hydraulic line inspection, and bleeding procedures. Suspension System: Front fork service, seal replacement, oil specifications, rear shock absorber inspection and adjustment. Electrical System: Wiring diagrams, battery testing, charging system (stator and regulator/rectifier) diagnosis, lighting, starter motor, and switchgear. Chassis And Bodywork: Frame inspection, body panel removal and installation, seat, fairings, and accessory mounting. Diagnostic Troubleshooting: Step-by-step troubleshooting guides for common issues and component failures. Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug checks, chain adjustment (if applicable), brake fluid checks, tire pressure checks. Major Repairs: Engine rebuilds, transmission overhauls, suspension fork rebuilds, brake system repairs. Component Replacement: Detailed instructions for replacing wear items and major components. Troubleshooting Charts: Diagnostic flowcharts for identifying and resolving various operational problems. Technical Depth Depth Of Coverage: Comprehensive, covering from basic rider maintenance to full mechanical overhauls and electrical diagnostics. Diagnostic Capabilities: Detailed information for diagnosing electrical faults, fuel system issues, and mechanical component wear. 📊 Manual Specifications File Format Digital Format: PDF Print Quality Image Resolution: High-resolution scans for clear diagrams and text. Binding Type Physical Binding: N/A (Digital Format) Paper Type Physical Paper Type: N/A (Digital Format) Features Searchability: Searchable text for quick access to information. Printable: Printable pages for hands-on workshop use. ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, single-cylinder Displacement: 124.9 cc Bore X Stroke: 57 mm x 48.6 mm Cooling System: Liquid-cooled Valvetrain: SOHC, 2 valves per cylinder Performance Max Power: Approx. 10.5 kW (14.3 PS) @ 8,500 rpm (Europe) Max Torque: Approx. 12 Nm @ 6,500 rpm Fuel System Carburetor: Dell'Orto PHBH 28 DD (or similar specification) Fuel Type: Unleaded Gasoline (95 Octane Recommended) Lubrication Oil Type: SAE 10W-40 API SG or higher Oil Capacity: Approx. 1.1 Liters (with oil filter change) 🔧 Transmission Standard Transmission Type: Automatic CVT (Continuously Variable Transmission) Features Clutch Type: Automatic centrifugal clutch Drive Type: Belt drive 📐 Dimensions Exterior Length: Approx. 2000 mm Width: Approx. 770 mm Height: Approx. 1350 mm (seat height) Wheelbase: Approx. 1410 mm Weights Dry Weight: Approx. 155 kg Gross Vehicle Weight Rating: Approx. 310 kg Fuel Tank Capacity: Approx. 10.0 Liters (including reserve) 🛡️ Safety Features Ratings Crash Test Results: N/A (Motorcycle/Scooter segment generally not subjected to automotive-style crash tests) Active Features Braking System: Front: Hydraulic disc brake (single disc), Rear: Hydraulic disc brake (single disc). Lighting: Halogen headlight, taillight, and turn signals for visibility. Passive Features Frame Construction: Steel tube frame for structural integrity. Tires: Front: 120/70-15, Rear: 140/70-15 (typical sizes) 💡 Technology Features Infotainment Dashboard Instruments: Analog speedometer, tachometer, fuel gauge, coolant temperature gauge, odometer, trip meter, warning lights (oil, battery, indicators). Driver Assistance ABS Availability: Not typically available on this model year and displacement. Connectivity Charging Ports: No integrated USB or 12V power outlets usually found on this model, aftermarket options available. 🔧 Maintenance Service Intervals Engine Oil Change: Every 3,000 - 5,000 km or annually, whichever comes first. Air Filter Cleaning Replacement: Clean every 5,000 km, replace every 10,000 km or as needed. Spark Plug Replacement: Every 8,000 - 10,000 km. Cvt Belt Inspection Replacement: Inspect every 5,000 km, replace approximately every 15,000 - 20,000 km or when signs of wear appear. Brake Fluid Replacement: Every 2 years or as recommended by the manual. Coolant Replacement: Every 2 years or as recommended. Fluid Specifications Engine Oil: SAE 10W-40 API SG (or higher) semi-synthetic or full-synthetic motorcycle oil. Coolant: Ethylene glycol-based coolant with corrosion inhibitors, mixed 50/50 with distilled water. Brake Fluid: DOT 4. Known Issues Charging System Faults: Occasional regulator/rectifier failures leading to battery charging issues. Cvt...
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Aprilia Leonardo 125 2002 Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
Leonardo 125
Year:
2002
Codes
Model Code:
AP06
👋 Introduction
Market Position
Vehicle Segment:
Premium 125cc Scooter (Urban Commuter)
Target Audience:
Riders seeking a stylish and reliable urban scooter with a sporty heritage.
Competitive Analysis
Key Competitors:
Piaggio Beverly 125, Gilera Nexus 125, Yamaha X-Max 125, Honda Pantheon 125.
Key Features
Design Philosophy:
Italian design flair combined with practical urban commuting features.
Handling:
Sport-oriented chassis and suspension tuning typical of Aprilia's motorcycle lineage.
Ergonomics:
Comfortable riding position for city use, ample legroom.
Storage:
Under-seat storage compartment for a helmet, glove box.
📋 Manual Details
Coverage Areas
Manual Type:
Factory Service Repair Manual
Language:
English
Format:
Digital (Likely PDF)
Page Count
Estimated Page Count:
~200-300 Pages
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete engine disassembly, assembly, inspection, and overhaul procedures for the 125cc 4-stroke engine.
Fuel System:
Carburetor adjustment, cleaning, and overhaul; fuel pump operation and testing; fuel tank and line maintenance.
Ignition System:
Spark plug specifications, ignition timing, CDI unit testing, and troubleshooting.
Cooling System:
Radiator and fan operation, coolant specifications and replacement, water pump inspection and repair.
Transmission System:
CVT (Continuously Variable Transmission) component inspection, belt replacement, clutch and variator servicing.
Brakes System:
Front and rear brake caliper service, master cylinder overhaul, brake fluid replacement, hydraulic line inspection, and bleeding procedures.
Suspension System:
Front fork service, seal replacement, oil specifications, rear shock absorber inspection and adjustment.
Electrical System:
Wiring diagrams, battery testing, charging system (stator and regulator/rectifier) diagnosis, lighting, starter motor, and switchgear.
Chassis And Bodywork:
Frame inspection, body panel removal and installation, seat, fairings, and accessory mounting.
Diagnostic Troubleshooting:
Step-by-step troubleshooting guides for common issues and component failures.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, spark plug checks, chain adjustment (if applicable), brake fluid checks, tire pressure checks.
Major Repairs:
Engine rebuilds, transmission overhauls, suspension fork rebuilds, brake system repairs.
Component Replacement:
Detailed instructions for replacing wear items and major components.
Troubleshooting Charts:
Diagnostic flowcharts for identifying and resolving various operational problems.
Technical Depth
Depth Of Coverage:
Comprehensive, covering from basic rider maintenance to full mechanical overhauls and electrical diagnostics.
Diagnostic Capabilities:
Detailed information for diagnosing electrical faults, fuel system issues, and mechanical component wear.
📊 Manual Specifications
File Format
Digital Format:
PDF
Print Quality
Image Resolution:
High-resolution scans for clear diagrams and text.
Binding Type
Physical Binding:
N/A (Digital Format)
Paper Type
Physical Paper Type:
N/A (Digital Format)
Features
Searchability:
Searchable text for quick access to information.
Printable:
Printable pages for hands-on workshop use.
⚙️ Engine Specifications
Primary Engine
Engine Type:
Four-stroke, single-cylinder
Displacement:
124.9 cc
Bore X Stroke:
57 mm x 48.6 mm
Cooling System:
Liquid-cooled
Valvetrain:
SOHC, 2 valves per cylinder
Performance
Max Power:
Approx. 10.5 kW (14.3 PS) @ 8,500 rpm (Europe)
Max Torque:
Approx. 12 Nm @ 6,500 rpm
Fuel System
Carburetor:
Dell'Orto PHBH 28 DD (or similar specification)
Fuel Type:
Unleaded Gasoline (95 Octane Recommended)
Lubrication
Oil Type:
SAE 10W-40 API SG or higher
Oil Capacity:
Approx. 1.1 Liters (with oil filter change)
🔧 Transmission
Standard
Transmission Type:
Automatic CVT (Continuously Variable Transmission)
Features
Clutch Type:
Automatic centrifugal clutch
Drive Type:
Belt drive
📐 Dimensions
Exterior
Length:
Approx. 2000 mm
Width:
Approx. 770 mm
Height:
Approx. 1350 mm (seat height)
Wheelbase:
Approx. 1410 mm
Weights
Dry Weight:
Approx. 155 kg
Gross Vehicle Weight Rating:
Approx. 310 kg
Fuel Tank Capacity:
Approx. 10.0 Liters (including reserve)
🛡️ Safety Features
Ratings
Crash Test Results:
N/A (Motorcycle/Scooter segment generally not subjected to automotive-style crash tests)
Active Features
Braking System:
Front: Hydraulic disc brake (single disc), Rear: Hydraulic disc brake (single disc).
Lighting:
Halogen headlight, taillight, and turn signals for visibility.
Passive Features
Frame Construction:
Steel tube frame for structural integrity.
Tires:
Front: 120/70-15, Rear: 140/70-15 (typical sizes)
💡 Technology Features
Infotainment
Dashboard Instruments:
Analog speedometer, tachometer, fuel gauge, coolant temperature gauge, odometer, trip meter, warning lights (oil, battery, indicators).
Driver Assistance
ABS Availability:
Not typically available on this model year and displacement.
Connectivity
Charging Ports:
No integrated USB or 12V power outlets usually found on this model, aftermarket options available.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 3,000 - 5,000 km or annually, whichever comes first.
Air Filter Cleaning Replacement:
Clean every 5,000 km, replace every 10,000 km or as needed.
Spark Plug Replacement:
Every 8,000 - 10,000 km.
Cvt Belt Inspection Replacement:
Inspect every 5,000 km, replace approximately every 15,000 - 20,000 km or when signs of wear appear.
Brake Fluid Replacement:
Every 2 years or as recommended by the manual.
Coolant Replacement:
Every 2 years or as recommended.
Fluid Specifications
Engine Oil:
SAE 10W-40 API SG (or higher) semi-synthetic or full-synthetic motorcycle oil.
Coolant:
Ethylene glycol-based coolant with corrosion inhibitors, mixed 50/50 with distilled water.
Brake Fluid:
DOT 4.
Known Issues
Charging System Faults:
Occasional regulator/rectifier failures leading to battery charging issues.
Cvt Wear:
Variator rollers and clutch shoes can wear over time, affecting acceleration and top speed.
Carburetor Tuning:
Can be sensitive to altitude and temperature changes, requiring periodic adjustment.
Maintenance Parts
Oil Filter Part Number:
Refer to manual for specific Aprilia P/N or common aftermarket equivalents (e.g., Hiflofiltro HF183).
Air Filter Part Number:
Refer to manual for specific Aprilia P/N or common aftermarket equivalents.
Spark Plug Type:
NGK CR9E (or equivalent).
📚 Vehicle History
Brand Heritage
Manufacturer Origin:
Aprilia is an Italian manufacturer, renowned for its performance motorcycles and scooters.
Model Evolution
Leonardo Series:
The Leonardo line was Aprilia's upscale scooter offering, featuring a blend of sporty performance and premium features, with 125cc, 150cc, and 250cc variants over its production life.
2002 Model Year:
Represents a mature iteration of the Leonardo 125, likely with minor updates from previous years.
Production
Manufacturing Location:
Italy
🏆 Awards & Recognition
Recognitions
Awards And Accolades:
While specific awards for the 2002 Leonardo 125 are not widely publicized, Aprilia as a brand has a strong racing heritage and consistently receives accolades for its performance and design across its product range.
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