APRILIA LEONARDO 250 Gebrauchsanweisung

www.serviceaprilia.com

workshopmanual

LEONARDO 250 - 300

1194 4

00/2004-04

8140782 UK

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INTRODUCTION

0 - 1

LEONARDO 250 - 300

INTRODUCTION 0

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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

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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

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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

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INTRODUCTION

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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

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INTRODUCTION

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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

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GENERAL INFORMATION

1 - 1

LEONARDO 250 - 300

GENERAL INFORMATION 1

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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

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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

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