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1999-2001 Aprilia 120(S)-154(S) Leonardo/Scarabeo Scooter Workshop Repair & Service Manual
Complete digital workshop service and repair manual written for the Aprilia 120(S)-154(S) Leonardo/Scarabeo (Rotax Engine) Scooter; Production model years: 1999 2000 2001. All styles covered (all models, and engines). It is in the cross-platform PDF document format so that it works like a charm on all kinds of devices.
This QUALITY manual is 100 COMPLETE and INTACT, no MISSING/CORRUPT pages/sections to freak you out! Buy from responsible seller and get INSTANT DOWNLOAD now without wasting your hard-owned money on uncertainty or surprise; this manual is exactly as described.
PRODUCT DETAILS:
Total Pages: 136 pages
File Format: PDF (Windows & Mac & Linux)
Language: English/Italian
Delivery: instant download link displayed on checkout page & emailed to you after payment
Protection: DRM-free; without any restriction
Printable: Yes
This COMPLETE official full workshop service repair manual includes:
* Detailed sub-steps expand on repair procedure information
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Numbered instructions guide you through every repair procedure step by step.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
* Numbered table of contents easy to use so that you can find the information you need fast.
* This manual also makes it easy to diagnose and repair problems with your machines electrical system.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* COMPLETE, Absolutely No Missing Pages!
* Official Service INFORMATION You Can Count On!
* Customer Satisfaction GUARANTEED
EXCERPT (1999-2001 Aprilia 120(S)-154(S) Leonardo/Scarabeo Scooter Service/Repair Manual):
CONTENTS
INDICE DEl CAPITOLI
Foreword ............................................................................................................... 2 Prefazione ............................................................................................................ 2
Important information lnformazioni importanti
Recurrent symbols ............................................................................................... 6
General precautions and safety rules ............. ...................................................... 6
Parts - list ............................................................................................................. 9
Engine serial number- position ............................................................................ 9
Technical data .................................................................................................... 11
Engine servicing schedule .................................................................................. 13
Servicing and repair requirements ...................................................................... 13
General notes on servicing and repair procedures .............................................. 15
Fault finding ......... ..................... ................... .. ... .................................................. 19
Service tools, equipment, sealing and lubricating agents ................................... 25
Standard tools .................................................................................................... 26
Measuring instruments ........ ............................................................................... 26
Fasteners ............................................................................................................ 26
Sealing and lubricating agents ............................................................................ 27
Torque wrench settings ....................................................................................... 32
Oil circuit ............................................................................................................ 35
Repairs without removing engine ........................................................................ 36
Removing engine from frame .............................................................................. 37
Positioning engine on stand ................................................................................ 38 Simboll ripetltivi ......................... .......... ............................................... .................. 6
Misure di prudenza generali e direttive di sicurezza ............................................ 6
Partlcolari - indice ................................................................................................ 9
Numero di serie del motore- posizione ............................................................... 9
Dati tecnici ......................................................................................................... 11
Tabella di manutenzione del motore .................................................................. 13
Esigenze per Ia manutenzione e riparazione ..................................................... 13
Note generali di procedimento per lavori di manutenzione e riparazione .......... 15
Ricerca di difetti .................................................................................................. 19
Attrezzi specifici, dispositlvi, materiale di consumo ........................................... 25
Attrezzi standard ............. ................................................................................... 26
Attrezzi di misura ............................................................................................... 26
Elementi di fissaggio .......................................................................................... 26
Materiali di consume .. .' ....................................................................................... 27
Copple di serraggio ............................................................................................ 32
Circuito dell'olio .................................................................................................. 35
Riparazioni senza togliere il motore ................................................................... 36
Smontaggio del motore dal telaio ........................... ... ......................................... 37
Posizionamento del motore sui supporto ............................................ ............... 38
Dismantling the engine Smontagg io del motore
Starter motor- remove ..................................................................................... 39
Variator cover- remove .............................................. .... ................................... 39
Carburetor hose and valve cover- remove ...................................................... 40
Locking crankshaft at top dead center ............................................................... 41
Timing chain- check ........................................................................................ 43
Chain tensioner and timing gear- remove ........................................................ 43
Cylinder head - remove .................................................................................... 44
Chain guide and chain tension guide- remove ................................................. 45
Cylinder- remove ...... ................................................. .................... .................. 45
Piston- remove ................................................................................................ 46
Oil filter and oil pressure switch- remove ........................................................ 47 Motorino d'avviamento - smontaggio ....... ........................................................ 39
Coperchio variatore- smontaggio ................................................................... 39
Manicotto carburatore e coperchio valvole- smontaggio ............................... .40
Bloccaggio dell'albero motore al punto morto superiore .................................... 41
Catena distribuzione- controllo ...................................................................... .43
Tendicatena e ingranaggio distribuzione- smontaggio .................................... 43
Testata- smontaggio .................................. ............................................. ........ 44
Pattino guidacatena e pattino tendicatena- smontaggio ........ ........................ .45
Cilindro - smontaggio ....................................................................................... 45
Pistone - smontaggio ....................................................................................... 46
Ignition and electric starter gearing - remove ................................................... 47
Oil pump- remove ........................................................................................... 49
Water pump- remove ....................................................................................... 49
Chain tension guide and timing chain - remove ................................................ 51
Oil strainer- remove ........................................................................................ 51
Variator- remove .............................................................................................. 52
Oil pressure valve .............................................................................................. 54
Transmission- remove ..................................................................................... 54
Half crankcase - separate ................................................................................ 57
Crankshaft- remove ........................................................................................ 58 Accensione e ruotismo per awiamento elettrico- smontaggio ........................ 47
Pompa dell' olio - smontaggio ........................................................................... 49
Pompa acqua - smontaggio .............................................................................. 49
Pattino tendicatena e catena distribuzione- smontaggio ................................. 51
Retino olio - smontaggio .................................................................................. 51
Variatore - smontaggio ..................................................................................... 52
Val vola pressione olio ......................................................................................... 54
Trasmissione- smontaggio .............................................................................. 54
Coppia semicarter - separazione ..................................................................... 57
Albero motore- smontaggio ............................................................................. 58
Servicing procedures lnterventi sulle varie parti
Crankcase .......................................................................................................... 59
Half crankcase, flywheel side (MS)- flywheel side servicing ........................... 61
Half crankcase, clutch side- removal and refitting of plain bearings,
ball bearings, oil seal, etc ................................................................................... 65
Transmission cover -servicing ........................................................................ 72
Crankshaft ...................................................... ............ ........................................ 76
Transmission ...................................................................................................... 78
Variator, primary drive side- check .................................................................. 79
Secondary drive ................................................................................................. 83
Timing gear ......................................................................................................... 87
Chain guide and chain tension guide .................................................................. 88
Oil pump and water pump gearing ...................................................................... 88
Oil pressure retaining valve ................................................................................ 90
Cylinder .............................................................................................................. 91
Piston and piston pin .......................................................................................... 91
Piston rings ........................................................................................................ 93
Cylinder head ...................................................................................................... 95
Valves ................................................................................................................ 98
Valve seats ......................................................................................................... 99
Rocker arms ..................................................................................................... 101
Thermostat - check (Leonardo 120 only) ... .................................................. 103
Valve cover ....................................................................................................... 104
Ignition .............................................................................................................. 105 Carter motore ... ................................................................................................ .. 59
Semicarter, lato volano (MS)- interventi lato volano ....................................... 61
Semicarter, lato frizione- smontaggio e montaggio delle bronzine,
cuscinetti a sfere, paraolio ecc ........................................................................... 65
Coperchio trasmissione - interventi ................................................................ 72
Albero motore .................................................................................................... 76
Trasmissione ...................................................................................................... 78
Variatore, lato trasmissione primaria- controllo .............................................. 79
Trasmissione secondaria ................................................................................... 83
Comando della distribuzione .............................................................................. 87
Patti no guidacatena e patti no tendicatena ......................................................... 88
lngranaggio per pompa dell'olio e pompa dell'acqua ......................................... 88
Valvola di sovrappressione olio .......................................................................... 90
Cilindro ............................................................................................... : ............... 91
Pistone e spinotto .............................................................................................. 91
Segmenti ............................................................................................................ 93
Testata ................................................................................................................ 95
Valvole ................................................................................................................ 98
Sede valvola ....................................................................................................... 99
Bilancieri .......................................................................................................... 101
Termostato - controllo (solo Leonardo 120) ................................................. 103
Coperchio valvola ............................................................................................. 1 04
Accensione ...................................................................................................... 105
Ignition cover .................................................................................................... 108
Spark plug .................. ............. .... ............... .......................... .. .. .. .............. .. ...... 109
Electric starter gearing .......................................... ......................................... .. 110
Idle gear ......................................................................... .................................. 111
Starter motor ........ .................................................... .. .. .. ........ .. .. .. ................. ... 111 Coperchio accensione ...................................................... ................................ 108
Candela ................................................................................................ ............ 109
Ruotismo per awiamento elettrico ................................................................... 110
Ruota Iibera ........... .... .. .. .............................................. ................................... .. 111
Motorino d'avviamento ............................... .... ........ ............ .............................. 111
Reassembling the engine Rimontaggio del motore
Half crankcase, flywheel side ........... .... .. .................................. ........................ 112
Half crankcase, clutch side .................... ............... ............ .... .................. .. ....... 113
Oil strainer and magnetic drain plug - refit ............................................ ......... 119
Piston - refit ........................ .. .. ....................................................................... 120
Cylinder- refit ..................................... ...................................... ...................... 121
Chain guide and chain tension guide- refit .................................................... 123
Cylinder head- refit ........................................ .. .. .. .......................................... 123
Chain tensioner- refit ..................................................................................... 124
Valve clearance- adjust ................................................... .. .. .......................... 125
Oil filter- refit .. ...................................... .. ..... .. .. .............................................. 126
Flywheel side components- refit ................................................................... 126
Water pump, idle gear and ignition cover- refit .............................................. 127
Carburetor hose- refit ........ ............................................ .. .. ................ ... ......... 130
Starter motor - install ............................ ......................................................... 130
Variator cover - refit ... ................. .................................................................... 130
Refitting engine onto frame ......................................................................... .. .... 131
Filling ................................. ............................................... .. .............................. 131
Engine test ....................................................................................................... 133 Semi carter motore, Ia to volano .................................................................. ...... 112
Semi carter, lato frizione ............................................................ ................. ...... 113
Retino olio e vite magnetica- montaggio .......... ............................................ 119
Pistone - montaggio .............. ... ..................................................... ................. 120
Cilindro- montaggio ................. .... .. ......... ... .. .. ..................... .. .. .. .. .. .. ............... 121
Patti no guidacatena e patti no tendicatena- montaggio .... ........ ..................... 123
Testata - montaggio ........................................................................... ............ 123
Tendicatena- montaggio ........................... .................... ................................ 124
Gioco val vole - registrazione ..................... .................. ....... ........................... 125
Filtro dell'olio - montaggio .......................... .................................................... 126
Componenti allato volano - montaggio ......................................................... 126
Pompa acqua, ruota Iibera e coperchio accensione - montaggio .................. 127
Manicotto carburatore - montaggio ......... ................................... .. .. .. .............. 130
Motorino d'awiamento - installazione ........... ............ .................................... 130
Coperchio variatore- montaggio ........ ..... ..... ................................................. 130
Rimontaggio del motore nel telaio ............ .. ...................................................... 131
Riempimento liquidi .......................................................................................... 131
Prova motore ........................................................................... ......................... 133
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