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Aprilia Mojito 50 125 150 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Aprilia Model: Mojito Engine Variants Covered: 50cc, 125cc, 150cc Codes Engine Code General: Varies by specific engine displacement and generation (e.g., 50cc typically Piaggio Hi-PER 2, 125/150cc Rotax or Piaggio LEADER) Generation Generation General: The Mojito has seen multiple iterations and engine updates over its production run. This manual likely covers models from the early 2000s through mid-2010s, encompassing both the original styling and later updates. 👋 Introduction Market Position Vehicle Segment: Lightweight scooter, popular for urban mobility and casual recreational use. Design Philosophy: The Aprilia Mojito is known for its distinctive retro styling, reminiscent of classic scooters, combined with modern engineering and performance. Competitive Analysis Competitors: Competes with other 50cc and 125cc scooters from brands like Vespa, Honda, Yamaha, Kymco, and SYM, particularly those emphasizing style and ease of use. Key Features Styling: Unique 'Mojito' styling with large diameter wheels (uncommon for scooters), elongated body, and distinctive front end. Engine Options: Availability of multiple engine sizes (50cc, 125cc, 150cc) to cater to different licensing requirements and rider preferences. Performance Focus: Designed for nimble handling and efficient urban commuting, with the larger engines offering more capable performance for inter-city travel. 📋 Manual Details Coverage Areas Manual Type: Factory Service Repair Manual Language: English Format: PDF Printability: Yes Compatibility: Windows, MAC Requirements: Adobe PDF Reader Delivery Method: Instant Download 📖 Manual Coverage Systems Covered Engine Mechanical: Complete disassembly, inspection, repair, and reassembly of 50cc and 125/150cc engines. This includes cylinder head, cylinder, piston, crankshaft, connecting rod, lubrication system (oil pump), cooling system (water pump for liquid-cooled variants), and timing components. Engine Electrical: Ignition unit, electric starter system components and troubleshooting, charging system components (stator, regulator/rectifier), and wiring diagrams. Transmission Drivetrain: Clutch (likely centrifugal clutch for 50cc, possibly multi-plate for 125/150cc), transmission internal components (gears, shafts, bearings - if applicable and separate from engine), final drive (gearbox oil and seals). Fuel System: Carburetor (specification, adjustment, cleaning, and overhaul), fuel lines, fuel pump (if applicable), fuel tank. Cooling System: Water pump maintenance and seal replacement (for liquid-cooled models), radiator, hoses, coolant specifications, and bleeding procedures. Suspension: Front fork disassembly, seal replacement, oil type and level specifications. Rear shock absorber (adjustment, replacement). Braking System: Brake caliper service, brake pad replacement, brake fluid type and bleeding procedures, master cylinder overhaul (if covered). Electrical System: Battery, lighting (headlight, taillight, indicators), horn, starter motor, wiring harnesses, fuses, switches, and diagnostic procedures. Chassis Frame: General chassis inspection, steering bearing maintenance, and component mounting. Procedures Included Maintenance Schedule: Includes recommended maintenance intervals for oil changes, filter replacements, spark plugs, brake checks, fluid flushes, and other routine servicing. Troubleshooting: Diagnostic guidance for common problems related to starting, engine performance, electrical systems, and other operational issues. Engine Overhaul: Detailed step-by-step instructions for complete engine teardown and rebuild, including torque specifications and clearances. Component Replacement: Procedures for replacing individual components such as pistons, rings, valves, bearings, seals, water pumps, oil pumps, and clutch elements. Electrical Diagnostics: Guidance on testing electrical circuits, components, and diagnosing faults using wiring diagrams. Suspension Service: Instructions for front fork seal replacement, oil changes, and basic rear shock absorber adjustments. Brake System Maintenance: Procedures for bleeding the brake system, replacing brake pads and fluid. Carburetor Tuning: Detailed steps for cleaning, rebuilding, and adjusting the carburetor for optimal performance. Lubrication System: Maintenance of the oil pump, oil filter (if applicable), and oil change procedures with specific fluid types. Technical Depth Depth: Comprehensive factory-level repair information suitable for professional technicians and advanced DIY enthusiasts. Covers everything from routine maintenance to complete engine rebuilding and electrical system diagnostics. 📊 Manual Specifications File Format File Format: PDF Searchability: Likely searchable text content, enabling quick navigation to specific topics. Resolution: Typically high resolution for clear text and diagrams. Print Quality Printability: Printable pages for on-site workshop use. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type 50Cc: 2-stroke, air-cooled (or liquid-cooled, depending on specific sub-model), single-cylinder (typically Piaggio Hi-PER 2 engine family). Engine Type 125/150Cc: 4-stroke, air-cooled or liquid-cooled, single-cylinder (often Piaggio LEADER or Rotax engine). Performance Horsepower 50Cc: Approx. 4-5 HP (varies by market and emissions regulations) Horsepower 125Cc: Approx. 10-12 HP (varies by market and engine type) Horsepower 150Cc: Approx. 12-14 HP (varies by market and engine type) Fuel System Carburetor Size 50Cc: Typically 17.5mm or 19mm (e.g., Dell'Orto PHVA/PHVB). Carburetor Size 125Cc: Typically 27.5mm or larger (e.g., Keihin or Dell'Orto). Fuel Delivery: Carburetor with manual choke or automatic enrichment device. Ignition Ignition System: Electronic ignition (CDI or digital electronic ignition). Lubrication Lubrication Type 2 Stroke: Premix or separate oil injection system. Oil Type 4 Stroke: API SG, JASO MA certified 4-stroke scooter oil, viscosity typically 5W-40 or 10W-40 (check manual for specific grade). Cooling Cooling System: Air-cooled for some variants, liquid-cooled for others...
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Aprilia Mojito 50 125 150 Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
Mojito
Engine Variants Covered:
50cc, 125cc, 150cc
Codes
Engine Code General:
Varies by specific engine displacement and generation (e.g., 50cc typically Piaggio Hi-PER 2, 125/150cc Rotax or Piaggio LEADER)
Generation
Generation General:
The Mojito has seen multiple iterations and engine updates over its production run. This manual likely covers models from the early 2000s through mid-2010s, encompassing both the original styling and later updates.
👋 Introduction
Market Position
Vehicle Segment:
Lightweight scooter, popular for urban mobility and casual recreational use.
Design Philosophy:
The Aprilia Mojito is known for its distinctive retro styling, reminiscent of classic scooters, combined with modern engineering and performance.
Competitive Analysis
Competitors:
Competes with other 50cc and 125cc scooters from brands like Vespa, Honda, Yamaha, Kymco, and SYM, particularly those emphasizing style and ease of use.
Key Features
Styling:
Unique 'Mojito' styling with large diameter wheels (uncommon for scooters), elongated body, and distinctive front end.
Engine Options:
Availability of multiple engine sizes (50cc, 125cc, 150cc) to cater to different licensing requirements and rider preferences.
Performance Focus:
Designed for nimble handling and efficient urban commuting, with the larger engines offering more capable performance for inter-city travel.
📋 Manual Details
Coverage Areas
Manual Type:
Factory Service Repair Manual
Language:
English
Format:
PDF
Printability:
Yes
Compatibility:
Windows, MAC
Requirements:
Adobe PDF Reader
Delivery Method:
Instant Download
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete disassembly, inspection, repair, and reassembly of 50cc and 125/150cc engines. This includes cylinder head, cylinder, piston, crankshaft, connecting rod, lubrication system (oil pump), cooling system (water pump for liquid-cooled variants), and timing components.
Engine Electrical:
Ignition unit, electric starter system components and troubleshooting, charging system components (stator, regulator/rectifier), and wiring diagrams.
Transmission Drivetrain:
Clutch (likely centrifugal clutch for 50cc, possibly multi-plate for 125/150cc), transmission internal components (gears, shafts, bearings - if applicable and separate from engine), final drive (gearbox oil and seals).
Fuel System:
Carburetor (specification, adjustment, cleaning, and overhaul), fuel lines, fuel pump (if applicable), fuel tank.
Cooling System:
Water pump maintenance and seal replacement (for liquid-cooled models), radiator, hoses, coolant specifications, and bleeding procedures.
Suspension:
Front fork disassembly, seal replacement, oil type and level specifications. Rear shock absorber (adjustment, replacement).
Braking System:
Brake caliper service, brake pad replacement, brake fluid type and bleeding procedures, master cylinder overhaul (if covered).
Electrical System:
Battery, lighting (headlight, taillight, indicators), horn, starter motor, wiring harnesses, fuses, switches, and diagnostic procedures.
Chassis Frame:
General chassis inspection, steering bearing maintenance, and component mounting.
Procedures Included
Maintenance Schedule:
Includes recommended maintenance intervals for oil changes, filter replacements, spark plugs, brake checks, fluid flushes, and other routine servicing.
Troubleshooting:
Diagnostic guidance for common problems related to starting, engine performance, electrical systems, and other operational issues.
Engine Overhaul:
Detailed step-by-step instructions for complete engine teardown and rebuild, including torque specifications and clearances.
Component Replacement:
Procedures for replacing individual components such as pistons, rings, valves, bearings, seals, water pumps, oil pumps, and clutch elements.
Electrical Diagnostics:
Guidance on testing electrical circuits, components, and diagnosing faults using wiring diagrams.
Suspension Service:
Instructions for front fork seal replacement, oil changes, and basic rear shock absorber adjustments.
Brake System Maintenance:
Procedures for bleeding the brake system, replacing brake pads and fluid.
Carburetor Tuning:
Detailed steps for cleaning, rebuilding, and adjusting the carburetor for optimal performance.
Lubrication System:
Maintenance of the oil pump, oil filter (if applicable), and oil change procedures with specific fluid types.
Technical Depth
Depth:
Comprehensive factory-level repair information suitable for professional technicians and advanced DIY enthusiasts. Covers everything from routine maintenance to complete engine rebuilding and electrical system diagnostics.
📊 Manual Specifications
File Format
File Format:
PDF
Searchability:
Likely searchable text content, enabling quick navigation to specific topics.
Resolution:
Typically high resolution for clear text and diagrams.
Print Quality
Printability:
Printable pages for on-site workshop use.
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type 50Cc:
2-stroke, air-cooled (or liquid-cooled, depending on specific sub-model), single-cylinder (typically Piaggio Hi-PER 2 engine family).
Engine Type 125/150Cc:
4-stroke, air-cooled or liquid-cooled, single-cylinder (often Piaggio LEADER or Rotax engine).
Performance
Horsepower 50Cc:
Approx. 4-5 HP (varies by market and emissions regulations)
Horsepower 125Cc:
Approx. 10-12 HP (varies by market and engine type)
Horsepower 150Cc:
Approx. 12-14 HP (varies by market and engine type)
Fuel System
Carburetor Size 50Cc:
Typically 17.5mm or 19mm (e.g., Dell'Orto PHVA/PHVB).
Carburetor Size 125Cc:
Typically 27.5mm or larger (e.g., Keihin or Dell'Orto).
Fuel Delivery:
Carburetor with manual choke or automatic enrichment device.
Ignition
Ignition System:
Electronic ignition (CDI or digital electronic ignition).
Lubrication
Lubrication Type 2 Stroke:
Premix or separate oil injection system.
Oil Type 4 Stroke:
API SG, JASO MA certified 4-stroke scooter oil, viscosity typically 5W-40 or 10W-40 (check manual for specific grade).
Cooling
Cooling System:
Air-cooled for some variants, liquid-cooled for others (especially 125/150cc).
🔧 Transmission
Standard
Transmission Type:
Automatic CVT (Continuously Variable Transmission) with centrifugal clutch.
Optional
Optional Transmission:
N/A (CVT is standard for this scooter type).
Features
Clutch Type:
Centrifugal automatic clutch, engages at higher RPMs.
Final Drive:
Gear reduction via gearbox, requiring specific gear oil.
Gear Oil Spec Final Drive:
GL-4 SAE 80W/90 gear oil (verify with manual).
📐 Dimensions
Exterior
Wheelbase General:
Approx. 1300mm - 1350mm (varies slightly by model year).
Wheel Size:
Unusually large for a scooter, typically 16-inch front and rear.
Weights
Dry Weight 50Cc:
Approx. 100-110 kg.
Dry Weight 125Cc:
Approx. 110-125 kg.
Fuel Capacity:
Approx. 7-9 Liters.
🛡️ Safety Features
Ratings
Safety Ratings:
N/A (Scooters typically do not undergo the same rigorous crash testing as cars).
Active Features
Braking System:
Front disc brake, rear drum or disc brake depending on model variant.
Lighting:
Halogen headlight, taillight, brake light, turn signals.
Passive Features
Frame Construction:
Steel tube frame providing structural integrity.
💡 Technology Features
Infotainment
Instrument Cluster:
Analog or digital instrument cluster displaying speed, fuel level, odometer, turn signals, and indicator lights.
Driver Assistance
ABS:
ABS was not a common feature on most Mojito models, especially the 50cc variants. Later 125/150cc models might have it as an option.
Connectivity
Connectivity Features:
N/A (No advanced connectivity features like Bluetooth or smartphone integration are typically found on these scooters).
🔧 Maintenance
Service Intervals
Oil Change Interval 4 Stroke:
Typically every 3,000 - 5,000 km or annually, whichever comes first (refer to manual for exact mileage).
Air Filter Replacement:
Inspect every 2,000 km, replace as needed or every 6,000-10,000 km.
Spark Plug Replacement:
Check and clean at 2,000 km intervals, replace approximately every 5,000-8,000 km.
Brake Fluid Flush:
Recommended every 2 years or 24,000 km.
Fluid Specifications
Coolant Type Liquid Cooled:
Ethylene glycol based coolant, 50/50 mix with distilled water. Check manual for specific brand/type.
Fork Oil Type Front Suspension:
Specific suspension fluid with specified viscosity and level (refer to manual for exact grade and quantity).
Known Issues
Carburetor Fouling:
Common in smaller scooters, especially if left unused for extended periods, leading to starting problems or rough idling.
Electrical Connections:
Corrosion or loosening of electrical connectors, particularly in humid environments, can cause intermittent electrical faults.
Water Pump Seals:
For liquid-cooled models, water pump seals can degrade over time, leading to coolant leaks.
Variator Roller Wear:
Variator rollers can wear unevenly, affecting acceleration and top speed.
📚 Vehicle History
Brand Heritage
Aprilia Heritage:
Aprilia, an Italian brand, has a rich history in motorcycle racing and a strong reputation for sporty and stylish scooters and motorcycles.
Model Evolution
Mojito Introduction:
First introduced in the late 1990s/early 2000s, the Mojito quickly established itself with its unique design and enjoyable riding experience.
Engine Updates:
Has seen updates to its engine lineup, including adoption of Piaggio's modern engine platforms to meet emissions standards and improve performance/reliability.
Production
Production Location:
Primarily manufactured in Italy.
🏆 Awards & Recognition
Recognitions
Design Awards:
The Mojito has often been praised for its distinctive and stylish design, often winning accolades for its aesthetic appeal in the scooter segment.
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