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1999-2012 Aprilia Habana Mojito 50 125 150 Service Repair Manual

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🏷️ Basic Information Identification Make: Aprilia Model: Habana / Mojito Engine Variants: 50cc, 125cc, 150cc Model Years Covered: 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010, 2011, 2012 Codes Chassis Codes: AP050000 (Habana 50), AP010000 (Habana 125), AP020000 (Mojito 150) Engine Codes: Various Piaggio/Rotax based engines for 50cc, Piaggio LEADER series for 125/150cc 👋 Introduction Market Position Target Audience: Aprilia Habana and Mojito owners, independent repair shops, and professional motorcycle technicians. Vehicle Segment: Lightweight scooter, urban mobility. Competitive Analysis Key Competitors: Vespa ET series, Honda Pantheon, Yamaha Majesty, Kymco People series. Key Features Scooter Design: Retro-styled scooters offering distinctive aesthetics and practical urban transport. Manual Value Proposition: Provides essential knowledge for maintaining and repairing these Italian scooters, empowering owners and saving on dealership service costs. 📋 Manual Details Coverage Areas Systems Covered: Engine, Transmission, Fuel System, Ignition System, Electrical System, Cooling System, Frame, Suspension, Brakes, Steering, Bodywork, Body Panels, Troubleshooting, Maintenance, Specifications Page Count Estimated Page Count: 500+ Manual Type Manual Type: Service Repair Manual Language Language: English Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Complete overhaul procedures for 50cc (2-stroke, air-cooled, typically Piaggio/Minarelli variants) and 125/150cc (4-stroke, 3-valve Piaggio LEADER series) engines. Includes cylinder, piston, crankshaft, connecting rod, valve train (for 4-stroke), and lubrication system. Fuel System: Carburetor (50cc) and Fuel Injection (125/150cc) system diagnosis, removal, installation, and adjustment. Includes fuel pump, fuel filter, and fuel lines. Ignition System: CDI ignition system for 50cc, electronic ignition for 125/150cc. Covers spark plugs, ignition coils, stator, and electronic control units (ECU). Transmission Drivetrain: Automatic CVT (Continuously Variable Transmission) system, including clutch, variator, drive belt, and reduction gears. Maintenance and repair procedures for all variants. Electrical System: Wiring diagrams for all models and years. Covers battery, charging system (alternator/stator), lighting, starting system, horn, indicators, and instrument cluster. Braking System: Front and rear brake systems (disc and drum depending on variant). Includes brake caliper service, brake pad replacement, master cylinder overhaul, brake fluid flush, and adjustment. Suspension Steering: Front fork (telescopic) and rear shock absorber maintenance and replacement. Steering system including handlebars, headset bearings, and tie rods (if applicable). Cooling System: Air-cooling for 50cc models. Liquid-cooling for 125/150cc models, including radiator, coolant pump, thermostat, hoses, and coolant type specifications. Bodywork Chassis: Body panel removal and installation, seat, storage compartments, and structural integrity checks. VIN identification and frame component details. Procedures Included Preventative Maintenance: Scheduled maintenance tasks, oil changes, filter replacements, spark plug checks, brake system inspections, tire pressure checks, and fluid level checks. Diagnostic Troubleshooting: Step-by-step troubleshooting guides for common starting issues, running problems, electrical faults, and performance degradation. Includes diagnostic flowcharts. Engine Repair: Detailed instructions for engine disassembly, component inspection, reassembly, and torque specifications for all internal engine parts. Transmission Repair: CVT belt replacement, roller replacement, clutch inspection and service, and gear reduction maintenance. Electrical Repair: Wiring harness repair, component testing (e.g., starter motor, alternator), and troubleshooting electrical circuits using wiring diagrams. Brake System Repair: Bleeding the brake system, replacing brake pads and shoes, caliper and master cylinder overhaul. Suspension Wheel Maintenance: Fork seal replacement, shock absorber mounting, wheel bearing service, and tire mounting/balancing. Bodywork Cosmetic Repair: Instructions for removing and refitting body panels, fairings, and trim pieces. Technical Depth Depth Of Coverage: Comprehensive. Covers routine maintenance to complete engine and chassis rebuilds. Suitable for both novice DIY mechanics and professional technicians. Diagnostic Capabilities: Detailed diagnostic procedures and fault code interpretations (where applicable). 📊 Manual Specifications File Format File Format: PDF Searchability: Searchable text for quick information retrieval. Print Quality Image Resolution: High-resolution images and diagrams for clarity. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine 50Cc Engine Type: 2-stroke, air-cooled, single-cylinder (various Piaggio/Minarelli derivations) 50Cc Bore Stroke: Approx. 39mm x 41.4mm 50Cc Compression Ratio: Approx. 7.4:1 - 8.2:1 125Cc Engine Type: 4-stroke, liquid-cooled, 3-valve, SOHC, single-cylinder (Piaggio LEADER) 125Cc Bore Stroke: Approx. 52mm x 58.6mm 125Cc Compression Ratio: Approx. 12.0:1 150Cc Engine Type: 4-stroke, liquid-cooled, 3-valve, SOHC, single-cylinder (Piaggio LEADER) 150Cc Bore Stroke: Approx. 57mm x 58.6mm 150Cc Compression Ratio: Approx. 11.5:1 Performance 50Cc Horsepower: Approx. 4-5 HP 125Cc Horsepower: Approx. 10-12 HP 150Cc Horsepower: Approx. 12-14 HP Fuel System 50Cc Fuel Delivery: Carburetor (e.g., Dell'Orto PHVA 17.5) 125 150Cc Fuel Delivery: Electronic Fuel Injection (EFI) 🔧 Transmission Standard Transmission Type: Automatic CVT (Continuously Variable Transmission) Optional Optional Transmission: N/A (All models are CVT automatic) Features Clutch Type: Automatic centrifugal dry clutch Drive Belt Maintenance: Service interval for drive belt inspection and replacement is crucial for proper performance. 📐 Dimensions Exterior Overall Length: Approx. 1800-1900 mm (Varies slightly by model) Overall Width: Approx. 700-750 mm Seat Height: Approx. 770-800 mm Weights Dry Weight: Approx. 100-115 kg (Varies by engine size) Fuel Tank Capacity: Approx. 7-9 Liters 🛡️ Safety Features Ratings Safety...
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1999-2012 Aprilia Habana Mojito 50 125 150 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
Habana / Mojito
Engine Variants:
50cc, 125cc, 150cc
Model Years Covered:
1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010, 2011, 2012
Codes
Chassis Codes:
AP050000 (Habana 50), AP010000 (Habana 125), AP020000 (Mojito 150)
Engine Codes:
Various Piaggio/Rotax based engines for 50cc, Piaggio LEADER series for 125/150cc
👋 Introduction
Market Position
Target Audience:
Aprilia Habana and Mojito owners, independent repair shops, and professional motorcycle technicians.
Vehicle Segment:
Lightweight scooter, urban mobility.
Competitive Analysis
Key Competitors:
Vespa ET series, Honda Pantheon, Yamaha Majesty, Kymco People series.
Key Features
Scooter Design:
Retro-styled scooters offering distinctive aesthetics and practical urban transport.
Manual Value Proposition:
Provides essential knowledge for maintaining and repairing these Italian scooters, empowering owners and saving on dealership service costs.
📋 Manual Details
Coverage Areas
Systems Covered:
Engine, Transmission, Fuel System, Ignition System, Electrical System, Cooling System, Frame, Suspension, Brakes, Steering, Bodywork, Body Panels, Troubleshooting, Maintenance, Specifications
Page Count
Estimated Page Count:
500+
Manual Type
Manual Type:
Service Repair Manual
Language
Language:
English
Format
Format:
Digital Download (PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete overhaul procedures for 50cc (2-stroke, air-cooled, typically Piaggio/Minarelli variants) and 125/150cc (4-stroke, 3-valve Piaggio LEADER series) engines. Includes cylinder, piston, crankshaft, connecting rod, valve train (for 4-stroke), and lubrication system.
Fuel System:
Carburetor (50cc) and Fuel Injection (125/150cc) system diagnosis, removal, installation, and adjustment. Includes fuel pump, fuel filter, and fuel lines.
Ignition System:
CDI ignition system for 50cc, electronic ignition for 125/150cc. Covers spark plugs, ignition coils, stator, and electronic control units (ECU).
Transmission Drivetrain:
Automatic CVT (Continuously Variable Transmission) system, including clutch, variator, drive belt, and reduction gears. Maintenance and repair procedures for all variants.
Electrical System:
Wiring diagrams for all models and years. Covers battery, charging system (alternator/stator), lighting, starting system, horn, indicators, and instrument cluster.
Braking System:
Front and rear brake systems (disc and drum depending on variant). Includes brake caliper service, brake pad replacement, master cylinder overhaul, brake fluid flush, and adjustment.
Suspension Steering:
Front fork (telescopic) and rear shock absorber maintenance and replacement. Steering system including handlebars, headset bearings, and tie rods (if applicable).
Cooling System:
Air-cooling for 50cc models. Liquid-cooling for 125/150cc models, including radiator, coolant pump, thermostat, hoses, and coolant type specifications.
Bodywork Chassis:
Body panel removal and installation, seat, storage compartments, and structural integrity checks. VIN identification and frame component details.
Procedures Included
Preventative Maintenance:
Scheduled maintenance tasks, oil changes, filter replacements, spark plug checks, brake system inspections, tire pressure checks, and fluid level checks.
Diagnostic Troubleshooting:
Step-by-step troubleshooting guides for common starting issues, running problems, electrical faults, and performance degradation. Includes diagnostic flowcharts.
Engine Repair:
Detailed instructions for engine disassembly, component inspection, reassembly, and torque specifications for all internal engine parts.
Transmission Repair:
CVT belt replacement, roller replacement, clutch inspection and service, and gear reduction maintenance.
Electrical Repair:
Wiring harness repair, component testing (e.g., starter motor, alternator), and troubleshooting electrical circuits using wiring diagrams.
Brake System Repair:
Bleeding the brake system, replacing brake pads and shoes, caliper and master cylinder overhaul.
Suspension Wheel Maintenance:
Fork seal replacement, shock absorber mounting, wheel bearing service, and tire mounting/balancing.
Bodywork Cosmetic Repair:
Instructions for removing and refitting body panels, fairings, and trim pieces.
Technical Depth
Depth Of Coverage:
Comprehensive. Covers routine maintenance to complete engine and chassis rebuilds. Suitable for both novice DIY mechanics and professional technicians.
Diagnostic Capabilities:
Detailed diagnostic procedures and fault code interpretations (where applicable).
📊 Manual Specifications
File Format
File Format:
PDF
Searchability:
Searchable text for quick information retrieval.
Print Quality
Image Resolution:
High-resolution images and diagrams for clarity.
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
50Cc Engine Type:
2-stroke, air-cooled, single-cylinder (various Piaggio/Minarelli derivations)
50Cc Bore Stroke:
Approx. 39mm x 41.4mm
50Cc Compression Ratio:
Approx. 7.4:1 - 8.2:1
125Cc Engine Type:
4-stroke, liquid-cooled, 3-valve, SOHC, single-cylinder (Piaggio LEADER)
125Cc Bore Stroke:
Approx. 52mm x 58.6mm
125Cc Compression Ratio:
Approx. 12.0:1
150Cc Engine Type:
4-stroke, liquid-cooled, 3-valve, SOHC, single-cylinder (Piaggio LEADER)
150Cc Bore Stroke:
Approx. 57mm x 58.6mm
150Cc Compression Ratio:
Approx. 11.5:1
Performance
50Cc Horsepower:
Approx. 4-5 HP
125Cc Horsepower:
Approx. 10-12 HP
150Cc Horsepower:
Approx. 12-14 HP
Fuel System
50Cc Fuel Delivery:
Carburetor (e.g., Dell'Orto PHVA 17.5)
125 150Cc Fuel Delivery:
Electronic Fuel Injection (EFI)
🔧 Transmission
Standard
Transmission Type:
Automatic CVT (Continuously Variable Transmission)
Optional
Optional Transmission:
N/A (All models are CVT automatic)
Features
Clutch Type:
Automatic centrifugal dry clutch
Drive Belt Maintenance:
Service interval for drive belt inspection and replacement is crucial for proper performance.
📐 Dimensions
Exterior
Overall Length:
Approx. 1800-1900 mm (Varies slightly by model)
Overall Width:
Approx. 700-750 mm
Seat Height:
Approx. 770-800 mm
Weights
Dry Weight:
Approx. 100-115 kg (Varies by engine size)
Fuel Tank Capacity:
Approx. 7-9 Liters
🛡️ Safety Features
Ratings
Safety Standards:
Meets relevant European safety standards for light motorcycles/scooters.
Active Features
Braking System:
Disc front brake, drum rear brake (most variants). Some later 125/150cc models may feature dual disc or ABS.
Lighting:
Halogen headlight, LED/incandescent tail and brake lights, turn signals.
Passive Features
Frame Construction:
Steel underbone frame providing structural integrity.
💡 Technology Features
Infotainment
Instrument Cluster:
Analog speedometer, fuel gauge, indicator lights. Some models may feature digital elements.
Driver Assistance
ABS Availability:
ABS was not standard on most models within this range, but may have been an option on later 125/150cc versions.
Connectivity
Connectivity Features:
N/A (No modern connectivity features like Bluetooth or smartphone integration expected for this era).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000 - 5,000 km or annually (for 4-stroke), or as specified in manual for 2-stroke pre-mix or oil injection system.
Air Filter Service:
Inspect every 5,000 km, replace as needed or every 10,000 km.
Spark Plug Replacement:
Every 6,000 - 10,000 km depending on type.
Cvt Belt Replacement:
Every 10,000 - 15,000 km depending on usage and model.
Valve Clearance Adjustment:
Every 10,000 - 12,000 km (for 4-stroke models).
Fluid Specifications
Engine Oil Type:
For 4-stroke: SAE 5W-40 Synthetic or Semi-synthetic API SG/SH/SJ. For 2-stroke: 2-stroke specific oil for oil injection or pre-mix.
Coolant Type:
Ethylene glycol-based antifreeze with water (50/50 mix) for liquid-cooled models.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Known Issues
Common Problems:
CVT belt wear, carburetor tuning issues (50cc), electrical connector corrosion, aging fuel lines, weak starter solenoids, potential head gasket leaks (4-stroke) due to age.
Preventative Measures:
Regular maintenance, keeping the scooter clean and dry, using quality parts, and addressing minor issues promptly before they escalate.
📚 Vehicle History
Brand Heritage
Aprilia History:
Aprilia is an Italian manufacturer with a strong racing heritage, known for performance-oriented motorcycles and scooters.
Model Evolution
Habana Mojito Introduction:
Introduced in the late 1990s, these scooters were designed with a distinctive retro aesthetic, targeting riders seeking style and practicality.
Engine Updates:
Early models featured Piaggio or Minarelli 50cc 2-stroke engines. Later models, particularly the 125cc and 150cc, adopted the reliable Piaggio LEADER 4-stroke engine family.
Production
Manufacturing Location:
Primarily Italy
🏆 Awards & Recognition
Recognitions
Design Awards:
The retro styling of the Habana and Mojito models has often been praised for its unique appeal and classic design cues.
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