Aprilia Habana Mojito 50 125 150 1999 Full Service Repair Manual
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🏷️ Basic Information Identification Make: Aprilia Model: Habana / Mojito Year: 1999 Sub Model Variants: 50, 125, 150 Chassis Codes: Various, specific to engine displacement and model variant (e.g., AE, AR) 👋 Introduction Market Position Segment: Lightweight scooter, targeting urban commuting and recreational use. Positioned as stylish and practical. Competitive Analysis Competitors 1999: Competes with other 50cc, 125cc, and 150cc scooters of the era, such as Vespa, Piaggio, Honda (Dio, SH series), Yamaha (Jog, Majesty), and Kymco models. Key Features Design Styling: Retro, 'vintage' inspired design, often characterized by chrome accents, rounded lines, and distinctive headlight styling. Engine Variants: Offered in 50cc, 125cc, and 150cc displacements, providing options for different licensing requirements and performance expectations. 📋 Manual Details Coverage Areas Systems Covered: Engine, Fuel System, Ignition System, Cooling System, Exhaust System, Transmission (Automatic CVT), Drivetrain, Chassis, Suspension (Front and Rear), Steering, Brakes (Front and Rear), Electrical System, Lighting, Instruments, Bodywork, Seat, Fuel Tank, Maintenance, Troubleshooting, Diagrams, Specifications Page Count Page Count: Extensive (Specific number not provided, but described as 'very detailed') Manual Type Manual Type: Full Service Repair Manual Language Language: English (Assumed based on product description and common manual translations) Format Format: Digital (Likely PDF, based on description of containing 'everything') 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed disassembly, assembly, inspection, and repair of all engine components, including cylinder, piston, crankshaft, connecting rod, valves, camshaft (if applicable), timing mechanism, and seals. Fuel System: Carburetor adjustment, cleaning, and overhaul (specifics for Dell'Orto or similar), fuel pump inspection, fuel filter replacement, fuel line maintenance. Ignition System: Spark plug specifications, ignition timing adjustment, CDI unit testing, stator and rotor inspection, wiring diagrams for ignition circuits. Cooling System: For liquid-cooled variants (if applicable), radiator, water pump, thermostat, coolant type, and flush procedures. For air-cooled, cylinder head cooling fins and airflow management. Transmission Drivetrain: CVT (Continuously Variable Transmission) operation, variator disassembly/assembly, clutch inspection and replacement, drive belt inspection and replacement, final drive gear oil change and inspection. Brakes: Brake fluid specifications and bleeding procedures, brake pad replacement, caliper overhaul, brake disc inspection, drum brake adjustment and relining (if applicable). Suspension Steering: Front fork oil change and seal replacement, rear shock absorber inspection and replacement, steering head bearing adjustment and replacement, handlebar assembly. Electrical System: Battery maintenance and testing, starter motor operation, charging system (alternator/stator), fuses, wiring diagrams for all circuits, lighting system troubleshooting, horn, indicators. Procedures Included Preventive Maintenance: Detailed steps for routine checks and replacements, including oil changes, filter replacements (air, fuel, oil), spark plug checks, brake adjustments, tire pressure, chain lubrication (if applicable). Troubleshooting: Systematic diagnostic procedures for common and uncommon problems, fault finding charts, identification of symptoms and potential causes for engine, electrical, and mechanical issues. Component Overhaul: Step-by-step instructions for the complete disassembly, cleaning, inspection, measurement, repair, and reassembly of major components like the engine, carburetor, transmission, and brakes. Wiring Diagrams: Comprehensive, clearly labeled wiring schematics for all electrical systems, aiding in diagnostics and repairs. Technical Depth Depth: Comprehensive rebuild level, covering everything from basic fluid changes and adjustments to complete engine and transmission overhauls. Includes detailed torque specifications, clearances, and measurement procedures. 📊 Manual Specifications File Format File Format: PDF (Portable Document Format) - highly probable for accessibility and searchability. Print Quality Print Quality: High Resolution - designed to be clear and legible when printed, with sharp text and diagrams. Binding Type Binding Type: N/A (Digital format, but would typically be spiral-bound or perfect-bound if printed for workshop use) Paper Type Paper Type: N/A (Digital format, but original manuals often used durable, glossy paper for diagrams) ⚙️ Engine Specifications Primary Engine 50Cc Type: 2-stroke, air-cooled, single-cylinder Displacement: 49.4 cc Primary Engine 125Cc Type: 4-stroke, air-cooled, single-cylinder (likely Piaggio LEADER engine architecture) Displacement: 124 cc Primary Engine 150Cc Type: 4-stroke, air-cooled, single-cylinder (likely Piaggio LEADER engine architecture) Displacement: 150 cc Performance 125Cc Horsepower: Approx. 10-12 HP @ 7500-8000 RPM (Estimate) Torque: Approx. 10-12 Nm @ 6000-7000 RPM (Estimate) Fuel System 50Cc Carburetor: Dell'Orto PHVA or similar (specific model number found in manual) Fuel System 125 150 Carburetor: Dell'Orto PHVA or similar (specific model number found in manual) Fuel System Fuel Type: Unleaded Gasoline (RON 91 or higher) Lubrication Oil Type 50Cc: 2-stroke premix or oil injection system (check manual for specific) Oil Type 125 150: 4-stroke SAE 10W-40 or 15W-50 motorcycle specific API SG or higher (check manual for precise spec) 🔧 Transmission Standard Type: Automatic Continuously Variable Transmission (CVT) Optional Optional Transmission: N/A (CVT is standard) Features Drive Belt: Specific part number and inspection intervals for drive belt wear and tension. Final Drive: Gear drive, requiring specific gear oil change intervals and specifications (e.g., SAE 80W-90). 📐 Dimensions Exterior Length: Approx. 1800-1900 mm (Varies slightly by model) Width: Approx. 700-750 mm Height: Approx. 1100-1150 mm Weights Dry Weight 50Cc: Approx. 90-100 kg Dry Weight 125Cc: Approx. 105-115 kg...
Various, specific to engine displacement and model variant (e.g., AE, AR)
👋 Introduction
Market Position
Segment:
Lightweight scooter, targeting urban commuting and recreational use. Positioned as stylish and practical.
Competitive Analysis
Competitors 1999:
Competes with other 50cc, 125cc, and 150cc scooters of the era, such as Vespa, Piaggio, Honda (Dio, SH series), Yamaha (Jog, Majesty), and Kymco models.
Key Features
Design Styling:
Retro, 'vintage' inspired design, often characterized by chrome accents, rounded lines, and distinctive headlight styling.
Engine Variants:
Offered in 50cc, 125cc, and 150cc displacements, providing options for different licensing requirements and performance expectations.
Extensive (Specific number not provided, but described as 'very detailed')
Manual Type
Manual Type:
Full Service Repair Manual
Language
Language:
English (Assumed based on product description and common manual translations)
Format
Format:
Digital (Likely PDF, based on description of containing 'everything')
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Detailed disassembly, assembly, inspection, and repair of all engine components, including cylinder, piston, crankshaft, connecting rod, valves, camshaft (if applicable), timing mechanism, and seals.
Fuel System:
Carburetor adjustment, cleaning, and overhaul (specifics for Dell'Orto or similar), fuel pump inspection, fuel filter replacement, fuel line maintenance.
Ignition System:
Spark plug specifications, ignition timing adjustment, CDI unit testing, stator and rotor inspection, wiring diagrams for ignition circuits.
Cooling System:
For liquid-cooled variants (if applicable), radiator, water pump, thermostat, coolant type, and flush procedures. For air-cooled, cylinder head cooling fins and airflow management.
Transmission Drivetrain:
CVT (Continuously Variable Transmission) operation, variator disassembly/assembly, clutch inspection and replacement, drive belt inspection and replacement, final drive gear oil change and inspection.
Brakes:
Brake fluid specifications and bleeding procedures, brake pad replacement, caliper overhaul, brake disc inspection, drum brake adjustment and relining (if applicable).
Suspension Steering:
Front fork oil change and seal replacement, rear shock absorber inspection and replacement, steering head bearing adjustment and replacement, handlebar assembly.
Electrical System:
Battery maintenance and testing, starter motor operation, charging system (alternator/stator), fuses, wiring diagrams for all circuits, lighting system troubleshooting, horn, indicators.
Procedures Included
Preventive Maintenance:
Detailed steps for routine checks and replacements, including oil changes, filter replacements (air, fuel, oil), spark plug checks, brake adjustments, tire pressure, chain lubrication (if applicable).
Troubleshooting:
Systematic diagnostic procedures for common and uncommon problems, fault finding charts, identification of symptoms and potential causes for engine, electrical, and mechanical issues.
Component Overhaul:
Step-by-step instructions for the complete disassembly, cleaning, inspection, measurement, repair, and reassembly of major components like the engine, carburetor, transmission, and brakes.
Wiring Diagrams:
Comprehensive, clearly labeled wiring schematics for all electrical systems, aiding in diagnostics and repairs.
Technical Depth
Depth:
Comprehensive rebuild level, covering everything from basic fluid changes and adjustments to complete engine and transmission overhauls. Includes detailed torque specifications, clearances, and measurement procedures.
📊 Manual Specifications
File Format
File Format:
PDF (Portable Document Format) - highly probable for accessibility and searchability.
Print Quality
Print Quality:
High Resolution - designed to be clear and legible when printed, with sharp text and diagrams.
Binding Type
Binding Type:
N/A (Digital format, but would typically be spiral-bound or perfect-bound if printed for workshop use)
Paper Type
Paper Type:
N/A (Digital format, but original manuals often used durable, glossy paper for diagrams)
Specific part number and inspection intervals for drive belt wear and tension.
Final Drive:
Gear drive, requiring specific gear oil change intervals and specifications (e.g., SAE 80W-90).
📐 Dimensions
Exterior
Length:
Approx. 1800-1900 mm (Varies slightly by model)
Width:
Approx. 700-750 mm
Height:
Approx. 1100-1150 mm
Weights
Dry Weight 50Cc:
Approx. 90-100 kg
Dry Weight 125Cc:
Approx. 105-115 kg
Curb Weight 150Cc:
Approx. 110-120 kg
Cargo
Storage:
Under-seat storage compartment, often designed to hold a helmet. Glove box compartment.
🛡️ Safety Features
Ratings
Safety Standards:
Meets all applicable European safety standards for light motorcycles/scooters of the era.
Active Features
Brakes:
Disc brake front, drum brake rear (standard configuration for most models). Some variants might have disc rear.
Lighting:
Headlight, taillight, brake light, turn signals (front and rear).
Passive Features
Frame:
Steel tube frame, providing structural integrity.
Tires:
Tubed tires typical for the era. Specific sizes and pressure recommendations found in manual.
💡 Technology Features
Infotainment
Dashboard:
Analog speedometer, fuel gauge, odometer, indicator lights (turn signals, high beam, oil warning on 2-stroke).
Driver Assistance
Features:
Basic scooter technology, no advanced driver assistance systems. Focus on mechanical reliability and ease of use.
Connectivity
Features:
N/A (No modern connectivity features like Bluetooth or USB ports on this model).
🔧 Maintenance
Service Intervals
Oil Change 125 150:
Every 3,000-5,000 km or annually (check manual for specific mileage and time-based intervals).
Drive Belt Check:
Inspect every 6,000 km, replace as needed based on wear.
Air Filter Check:
Clean every 3,000 km, replace as needed.
Spark Plug Replace:
Replace every 5,000-10,000 km depending on plug type and condition.
Fluid Specifications
Brake Fluid:
DOT 4 (or specified equivalent by Aprilia).
Gear Oil:
SAE 80W-90 Hypoid gear oil (check manual for capacity).
Known Issues
Carburetor Cleaning:
Carburetors can be sensitive to fuel quality and require periodic cleaning/adjustment, especially on the 50cc 2-stroke model.
Electrical Connections:
As with many scooters of this era, electrical connections can corrode over time, leading to intermittent faults. Manual provides diagnostic steps.
Cooling System Leaks:
For liquid-cooled variants, potential for minor coolant leaks at hose connections if not maintained.
📚 Vehicle History
Brand Heritage
Manufacturer:
Aprilia is an Italian manufacturer renowned for its performance-oriented motorcycles and scooters.
Model Evolution
Segment Introduction:
The Habana/Mojito line was introduced to capitalize on the retro-scooter trend, offering a stylish alternative to more utilitarian models.
Production
Production Era:
The Habana/Mojito was produced through the late 1990s and early 2000s, with variations and updates over its lifespan. This manual covers the 1999 model year.
🏆 Awards & Recognition
Recognitions
Awards:
Specific awards for the 1999 model are not prominently documented, but Aprilia scooters generally receive positive reviews for style and performance in their class.