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Aprilia Leonardo 125 1997-2003 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Aprilia Model: Leonardo 125 Model Variant: 125cc Production Years Covered: 1997-2003 Codes Chassis Code: AP06 👋 Introduction Market Position Category: Maxi-scooter Target Audience: Commuters, urban riders seeking comfort and practicality. Competitive Analysis Key Competitors: Piaggio Skipper 125, Yamaha Majesty 125, Honda Pantheon 125. Key Features Design: Elegant Italian styling, comfortable ergonomics, ample under-seat storage. Engine Type: Liquid-cooled, four-stroke engine. Transmission Type: Automatic Continuously Variable Transmission (CVT). 📋 Manual Details Coverage Areas Manual Type: Factory Service Repair Manual Language: English Format: Digital (PDF) Page Count Estimated Page Count: 250+ 📖 Manual Coverage Systems Covered Engine Mechanical: Full overhaul procedures, cylinder head, piston, crankshaft, connecting rod, valve timing, lubrication system, cooling system. Fuel System: Carburetor identification, adjustment, cleaning, and overhaul; fuel pump; fuel lines; fuel tank. Ignition System: CDI unit, ignition coil, spark plug specifications, timing adjustment. Cooling System: Radiator, water pump, thermostat, coolant specifications, bleeding procedures. Transmission: Automatic transmission (CVT) overhaul, belt replacement, clutch assembly, variator, torque converter. Chassis And Frame: Frame inspection, alignment, fork assembly, steering head bearings, swingarm. Suspension Front: Telescopic fork service, oil change, seal replacement, spring specifications. Suspension Rear: Shock absorber specifications, adjustment, mounting, swingarm bearings. Brakes Front: Hydraulic disc brake system, caliper overhaul, pad replacement, master cylinder, brake fluid specifications, bleeding. Brakes Rear: Drum brake service, shoe replacement, adjustment, linkage. Wheels And Tires: Tire size specifications, pressure recommendations, wheel bearing service, rim specifications. Electrical System: Wiring diagrams, battery specifications, starter motor, charging system (alternator/stator), lighting, horn, indicators. Bodywork And Trim: Fairing removal and installation, seat, storage compartments, panel fitment. Procedures Included Routine Maintenance: Oil change intervals and specifications, filter replacement, spark plug replacement, air filter cleaning/replacement, brake checks, chain adjustment (if applicable to this model, likely not a chain drive), tire pressure checks. Troubleshooting: Diagnostic charts for common problems, symptom-based fault finding. Repair Procedures: Step-by-step instructions for all major mechanical and electrical component repairs and overhauls. Rebuilds: Complete engine rebuild, carburetor rebuild, transmission overhaul. Wiring Diagrams: Detailed electrical schematics for all vehicle systems. Technical Depth Depth: Comprehensive. Covers everything from basic fluid changes and checks to complete engine and transmission teardowns and rebuilds. 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text content for quick information retrieval. Printability: Printable for workshop use. Print Quality Image Resolution: High-resolution images and diagrams for clarity. Binding Type Binding: N/A (Digital Format) Paper Type Paper: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, liquid-cooled, SOHC, 2-valve Displacement: 124.9 cc (7.62 cu in) Bore X Stroke: 52.4 mm x 57.9 mm (2.06 x 2.28 in) Compression Ratio: 10.5:1 Power Output: Approx. 10.6 kW (14.2 hp) @ 9000 rpm (may vary slightly by market) Torque: Approx. 11.6 Nm (8.6 lb-ft) @ 7000 rpm (may vary slightly by market) Fuel System Carburetor Model: Dell'Orto PHBH 28 Fuel Type: Unleaded gasoline (95 RON recommended) Fuel Tank Capacity: Approx. 9.2 Liters (2.4 US gal) 🔧 Transmission Standard Transmission Type: Automatic CVT with torque converter Drive Type: Belt drive Features Clutch: Automatic centrifugal clutch Variator: Variable speed pulley system 📐 Dimensions Exterior Length: Approx. 1990 mm (78.3 in) Width: Approx. 750 mm (29.5 in) Height: Approx. 1350 mm (53.1 in) (seat height not specified, typically around 770-790mm) Wheelbase: Approx. 1380 mm (54.3 in) Weights Dry Weight: Approx. 144 kg (317.5 lbs) Wet Weight: Approx. 155 kg (341.7 lbs) 🛡️ Safety Features Ratings Crash Safety: N/A (Motorcycle/Scooter safety not rated by organizations like NHTSA/Euro NCAP) Active Features Braking System: Front disc brake, Rear drum brake. Passive Features Lighting: Halogen headlight, taillight, brake lights, turn signals. 💡 Technology Features Infotainment Dashboard Features: Analog speedometer, tachometer, fuel gauge, odometer, trip meter, indicator lights (turn signal, high beam, oil pressure). Driver Assistance ABS: Not typically equipped on this model. Connectivity Charging Port: No integrated USB or charging port from factory. 🔧 Maintenance Service Intervals Engine Oil Change: Every 5,000 km (3,000 miles) or 6 months. Oil Filter Replacement: At every oil change. Air Filter Cleaning: Every 5,000 km (3,000 miles), replace every 10,000 km (6,000 miles). Spark Plug Replacement: Every 10,000 km (6,000 miles). Transmission Oil Change: Every 10,000 km (6,000 miles) or 12 months. Cvt Belt Inspection: Every 10,000 km (6,000 miles), replacement typically around 20,000 km (12,000 miles). Fluid Specifications Engine Oil Type: SAE 10W-40, API SG or higher (check manual for exact specification, often Motul or Castrol recommended). Engine Oil Capacity: Approx. 1.2 Liters (1.3 US qt) with filter change. Coolant Type: Ethylene glycol-based antifreeze (50% mixture with distilled water). Brake Fluid Type: DOT 4 Transmission Oil Type: SAE 80W-90 API GL-4 Transmission Oil Capacity: Approx. 0.15 Liters (0.16 US qt) Known Issues Common Problems: Water pump seal leaks, voltage regulator failure, carburetor jetting issues leading to poor running, CVT belt wear, aging electrical connectors causing intermittent faults. Maintenance Recommendations: Regularly check coolant levels, inspect electrical connections...
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Aprilia Leonardo 125 1997-2003 Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
Leonardo 125
Model Variant:
125cc
Production Years Covered:
1997-2003
Codes
Chassis Code:
AP06
👋 Introduction
Market Position
Category:
Maxi-scooter
Target Audience:
Commuters, urban riders seeking comfort and practicality.
Competitive Analysis
Key Competitors:
Piaggio Skipper 125, Yamaha Majesty 125, Honda Pantheon 125.
Key Features
Design:
Elegant Italian styling, comfortable ergonomics, ample under-seat storage.
Engine Type:
Liquid-cooled, four-stroke engine.
Transmission Type:
Automatic Continuously Variable Transmission (CVT).
📋 Manual Details
Coverage Areas
Manual Type:
Factory Service Repair Manual
Language:
English
Format:
Digital (PDF)
Page Count
Estimated Page Count:
250+
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Full overhaul procedures, cylinder head, piston, crankshaft, connecting rod, valve timing, lubrication system, cooling system.
Fuel System:
Carburetor identification, adjustment, cleaning, and overhaul; fuel pump; fuel lines; fuel tank.
Ignition System:
CDI unit, ignition coil, spark plug specifications, timing adjustment.
Cooling System:
Radiator, water pump, thermostat, coolant specifications, bleeding procedures.
Transmission:
Automatic transmission (CVT) overhaul, belt replacement, clutch assembly, variator, torque converter.
Chassis And Frame:
Frame inspection, alignment, fork assembly, steering head bearings, swingarm.
Suspension Front:
Telescopic fork service, oil change, seal replacement, spring specifications.
Suspension Rear:
Shock absorber specifications, adjustment, mounting, swingarm bearings.
Brakes Front:
Hydraulic disc brake system, caliper overhaul, pad replacement, master cylinder, brake fluid specifications, bleeding.
Brakes Rear:
Drum brake service, shoe replacement, adjustment, linkage.
Wheels And Tires:
Tire size specifications, pressure recommendations, wheel bearing service, rim specifications.
Electrical System:
Wiring diagrams, battery specifications, starter motor, charging system (alternator/stator), lighting, horn, indicators.
Bodywork And Trim:
Fairing removal and installation, seat, storage compartments, panel fitment.
Procedures Included
Routine Maintenance:
Oil change intervals and specifications, filter replacement, spark plug replacement, air filter cleaning/replacement, brake checks, chain adjustment (if applicable to this model, likely not a chain drive), tire pressure checks.
Troubleshooting:
Diagnostic charts for common problems, symptom-based fault finding.
Repair Procedures:
Step-by-step instructions for all major mechanical and electrical component repairs and overhauls.
Rebuilds:
Complete engine rebuild, carburetor rebuild, transmission overhaul.
Wiring Diagrams:
Detailed electrical schematics for all vehicle systems.
Technical Depth
Depth:
Comprehensive. Covers everything from basic fluid changes and checks to complete engine and transmission teardowns and rebuilds.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text content for quick information retrieval.
Printability:
Printable for workshop use.
Print Quality
Image Resolution:
High-resolution images and diagrams for clarity.
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Four-stroke, liquid-cooled, SOHC, 2-valve
Displacement:
124.9 cc (7.62 cu in)
Bore X Stroke:
52.4 mm x 57.9 mm (2.06 x 2.28 in)
Compression Ratio:
10.5:1
Power Output:
Approx. 10.6 kW (14.2 hp) @ 9000 rpm (may vary slightly by market)
Torque:
Approx. 11.6 Nm (8.6 lb-ft) @ 7000 rpm (may vary slightly by market)
Fuel System
Carburetor Model:
Dell'Orto PHBH 28
Fuel Type:
Unleaded gasoline (95 RON recommended)
Fuel Tank Capacity:
Approx. 9.2 Liters (2.4 US gal)
🔧 Transmission
Standard
Transmission Type:
Automatic CVT with torque converter
Drive Type:
Belt drive
Features
Clutch:
Automatic centrifugal clutch
Variator:
Variable speed pulley system
📐 Dimensions
Exterior
Length:
Approx. 1990 mm (78.3 in)
Width:
Approx. 750 mm (29.5 in)
Height:
Approx. 1350 mm (53.1 in) (seat height not specified, typically around 770-790mm)
Wheelbase:
Approx. 1380 mm (54.3 in)
Weights
Dry Weight:
Approx. 144 kg (317.5 lbs)
Wet Weight:
Approx. 155 kg (341.7 lbs)
🛡️ Safety Features
Ratings
Crash Safety:
N/A (Motorcycle/Scooter safety not rated by organizations like NHTSA/Euro NCAP)
Active Features
Braking System:
Front disc brake, Rear drum brake.
Passive Features
Lighting:
Halogen headlight, taillight, brake lights, turn signals.
💡 Technology Features
Infotainment
Dashboard Features:
Analog speedometer, tachometer, fuel gauge, odometer, trip meter, indicator lights (turn signal, high beam, oil pressure).
Driver Assistance
ABS:
Not typically equipped on this model.
Connectivity
Charging Port:
No integrated USB or charging port from factory.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 5,000 km (3,000 miles) or 6 months.
Oil Filter Replacement:
At every oil change.
Air Filter Cleaning:
Every 5,000 km (3,000 miles), replace every 10,000 km (6,000 miles).
Spark Plug Replacement:
Every 10,000 km (6,000 miles).
Transmission Oil Change:
Every 10,000 km (6,000 miles) or 12 months.
Cvt Belt Inspection:
Every 10,000 km (6,000 miles), replacement typically around 20,000 km (12,000 miles).
Fluid Specifications
Engine Oil Type:
SAE 10W-40, API SG or higher (check manual for exact specification, often Motul or Castrol recommended).
Engine Oil Capacity:
Approx. 1.2 Liters (1.3 US qt) with filter change.
Coolant Type:
Ethylene glycol-based antifreeze (50% mixture with distilled water).
Brake Fluid Type:
DOT 4
Transmission Oil Type:
SAE 80W-90 API GL-4
Transmission Oil Capacity:
Approx. 0.15 Liters (0.16 US qt)
Known Issues
Common Problems:
Water pump seal leaks, voltage regulator failure, carburetor jetting issues leading to poor running, CVT belt wear, aging electrical connectors causing intermittent faults.
Maintenance Recommendations:
Regularly check coolant levels, inspect electrical connections for corrosion, ensure proper carburetor cleaning and adjustment.
📚 Vehicle History
Brand Heritage
Manufacturer:
Aprilia is an Italian manufacturer known for its sporty motorcycles and scooters.
Model Evolution
Segment Introduction:
The Leonardo line was Aprilia's entry into the growing maxi-scooter market of the late 1990s.
Market Placement:
Positioned as a comfortable, stylish, and practical urban commuter with a premium feel.
Production
Manufacturing Location:
Italy
🏆 Awards & Recognition
Recognitions
Market Reception:
Well-received for its styling and comfort in its segment during its production years.
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