APRILIA LEONARDO 250 Instruction manual

www.serviceaprilia.com
workshopmanual
LEONARDO 250 - 300
1194 4
00/2004-04
8140782 UK
WWW.PlanDeGraissage.ORG

INTRODUCTION
0 - 1
LEONARDO 250 - 300
INTRODUCTION 0
WWW.PlanDeGraissage.ORG

INTRODUCTION
0 - 2
LEONARDO 250 - 300
CONTENTS
0.1. INTRODUCTION .............................................................................................................................. 3
0.1.1. INTRODUCTION ..................................................................................................................... 3
0.1.2. REFERENCE MANUALS ........................................................................................................ 4
0.1.3. ABBREVIATIONS/SYMBOLS/CONVENTIONS...................................................................... 5
WWW.PlanDeGraissage.ORG

INTRODUCTION
0 - 3
LEONARDO 250 - 300
0.1. INTRODUCTION
0.1.1. INTRODUCTION
- This manual provides the information required for normal servicing.
- This publication is intended for use by aprilia dealerships and their qualified mechanics; many concepts have been
omitted inasmuch as their inclusion would be superfluous for such an audience. Since complete mechanical
explanations have not been included in this manual, the reader must be familiar with basic notions of mechanics,
as well as with basic repair procedures. Without such familiarity, repairs and checks could be ineffective and even
hazardous. Since the repair and vehicle check instructions are not exhaustive, special care must be taken to avoid
damage and injury. To ensure maximum customer satisfaction with the vehicle, aprilia spa continuously improves
its products and their documentation. The main technical modifications and changes in repair procedures are
communicated to all aprilia dealerships and agencies worldwide. Such modifications will be entered in subsequent
editions of the manual. In case of doubt regarding specific repairs or checks, contact the aprilia SERVICE
DEPARTMENT; we will be pleased to provide all necessary information and assistance as well as keeping you
updated on changes and modifications to the vehicle.
aprilia s.p.a. reserves the right to make changes to its products at any time, barring any such changes as may alter the
essential features of a product as specified in the relevant manual.
All rights of storage using electronic means, reproduction and total or partial adaptation, whatever the means adopted,
are reserved in all countries.
The mention of third parties’ products is only made for information purposes, and constitutes no engagement.
aprilia spa is not liable in any way for the performance or use of its products.
First edition: April 2004
Designed and printed by:
DECA srl
via Risorgimento, 23/1 - 48022 Lugo (RA) - Italy
Tel. +39 - 0545 35235
Fax +39 - 0545 32844
E-mail: [email protected]
www.decaweb.it
On behalf of:
aprilia S.p.A.
Via G. Galilei, 1 – 30033 Noale (VE) – Italy
Tel. +39 – (0)41 58 29 111
Fax +39 – (0)41 58 29 190
www.aprilia.com
www.serviceaprilia.com
WWW.PlanDeGraissage.ORG

INTRODUCTION
0 - 4
LEONARDO 250 - 300
0.1.2. REFERENCE MANUALS
Version 250 cc
SPARE PARTS CATALOGUES
aprilia part# (description)
OWNER’S MANUALS
aprilia part# (description)
8104730
8104804
8104805
8104806
ENGINE TECHNICAL MANUAL
aprilia part# (description)
8140778
8140779
8140780
8140781
8140782
CHASSIS PARTS TECHNICAL MANUAL
aprilia part# (description)
8140783
8140786
8140784
8140785
8140787
Version 300 cc
SPARE PARTS CATALOGUES
aprilia part# (description)
6572
OWNER’S MANUALS
aprilia part# (description)
8104730
8104804
8104805
8104806
ENGINE TECHNICAL MANUAL
aprilia part# (description)
8140778
8140779
8140780
8140781
8140782
CHASSIS PARTS TECHNICAL MANUAL
aprilia part# (description)
8140783
8140786
8140784
8140785
8140787
WWW.PlanDeGraissage.ORG

INTRODUCTION
0 - 5
LEONARDO 250 - 300
0.1.3. ABBREVIATIONS/SYMBOLS/CONVENTIONS
#= number
< = less than
> = greater than
≤= less than or equal to
≥= more than or equal to
~ = approximately
∞= infinity
°C = degrees Celsius (centigrade)
°F = degrees Fahrenheit
± = plus or minus
AC = alternating current
A = Ampere
Ah =Ampere per hour
API = American Petroleum Institute
HV = high voltage
AV/DC = Anti-Vibration Double Countershaft
bar = pressure measurement (1 bar =100 kPa)
DC. = Direct Current
cc = cubic centimetres
CO = carbon monoxide
CPU = Central Processing Unit
DIN = German industrial standards (Deutsche Industrie Norm)
DOHC = Double Overhead Camshaft
ECU = Electronic Control Unit
rpm = revolutions per minute
HC = unburnt hydrocarbons
ISC = Idle Speed Control
ISO = International Standardization Organization
Kg = kilograms
Kgm = kilogram metre (1 kgm =10 Nm)
km = kilometres
kph = kilometres per hour
kΩ= kilo Ohm
kPa = kiloPascal (1 kPa =0.01 bar)
KS = clutch side (from the German "Kupplungseite")
kW = kiloWatt
l= litres
LAP = racetrack lap
LED = Light Emitting Diode
LEFT
SIDE = left side
m/s = metres per second
max = maximum
mbar = millibar (1 mbar =0.1 kPa)
mi = miles
MIN = minimum
MPH = miles per hour
MS = flywheel side (from the German "Magnetoseite")
MΩ= megaOhm
N.A. = Not Available
N.O.M.M. = Motor Octane Number
N.O.R.M. = Research Octane Number
Nm = Newton metre (1 Nm =0.1 kgm)
Ω= ohm
PICK-UP = pick-up
BDC = Bottom Dead Centre
TDC = Top Dead Centre
PPC = Pneumatic Power Clutch
WWW.PlanDeGraissage.ORG

INTRODUCTION
0 - 6
LEONARDO 250 - 300
RIGHT
SIDE = right side
SAE = Society of Automotive Engineers
TEST = diagnostic check
T.B.E.I. = crown-head Allen screw
T.C.E.I. = cheese-head Allen screw
T.E. =hexagonal head
TP = flat head screw
TSI = Twin Spark Ignition
UPSIDE-
DOWN = inverted fork
V = Volt
W = Watt
Ø = Diameter
WWW.PlanDeGraissage.ORG

GENERAL INFORMATION
1 - 1
LEONARDO 250 - 300
GENERAL INFORMATION 1
WWW.PlanDeGraissage.ORG

GENERAL INFORMATION
1 - 2
LEONARDO 250 - 300
CONTENTS
1.1. STRUCTURE OF THE MANUAL..................................................................................................... 3
1.1.1. CONVENTIONS USED IN THE MANUAL .............................................................................. 3
1.1.2. SAFETY WARNINGS .............................................................................................................. 4
1.2. GENERAL RULES ........................................................................................................................... 5
1.2.1. BASIC SAFETY RULES .......................................................................................................... 5
1.3. DANGEROUS ELEMENTS..............................................................................................................8
1.3.1. WARNINGS ............................................................................................................................. 8
1.4. RUNNING-IN .................................................................................................................................. 12
1.4.1. RUNNING-IN RECOMMENDATIONS................................................................................... 12
1.5. VEHICLE IDENTIFICATION ..........................................................................................................13
1.5.1. POSITION OF THE SERIAL NUMBERS .............................................................................. 13
1.6. USING TOOLS AND SPARE PARTS............................................................................................ 14
1.6.1. SPARE PARTS...................................................................................................................... 14
1.7. SPECIFICATIONS.......................................................................................................................... 15
1.7.1. SPECIFICATIONS................................................................................................................. 15
1.7.2. HOW TO APPLY THE DECALS............................................................................................ 17
1.8. PRODUCTS ................................................................................................................................... 19
1.8.1. TABLE OF LUBRICANTS...................................................................................................... 19
1.8.2. PRODUCT APPLICATIONS.................................................................................................. 20
1.9. TIGHTENING ................................................................................................................................. 21
1.9.1. FASTENERS ......................................................................................................................... 21
WWW.PlanDeGraissage.ORG

GENERAL INFORMATION
1 - 3
LEONARDO 250 - 300
1.1. STRUCTURE OF THE MANUAL
1.1.1. CONVENTIONS USED IN THE MANUAL
•This manual is divided in sections and subsections, each covering a set of the most significant components. Refer
to the index of sections when consulting the manual.
•Unless expressly specified otherwise, assemblies are reassembled by reversing the dismantling procedure.
•The terms "right" and "left" are referred to the rider seated on the vehicle in the normal riding position.
•Motorcycle operation and basic maintenance are covered in the «OWNER'S MANUAL».
In this manual any variants are identified with these symbols:
optional
catalytic version
- all versions
MP national certification
SF European certification (EURO 1 limits)
VERSION:
Italy Greece Malaysia
United
Kingdom Holland Chile
Austria Switzerland Croatia
Portugal Denmark Australia
Finland Japan United
States of
America
Belgium Singapore Brazil
Germany Slovenia South Africa
France Israel New
Zealand
Spain South
Korea Canada
WWW.PlanDeGraissage.ORG