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APRILIA LEONARDO 250 Workshop Manual

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LEONARDO 250 - 300
1194 4
00/2004-04
workshopmanual
WWW.PlanDeGraissage.ORG

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  • Page 1 LEONARDO 250 - 300 1194 4 00/2004-04 workshopmanual WWW.PlanDeGraissage.ORG...
  • Page 2 INTRODUCTION LEONARDO 250 - 300 INTRODUCTION 0 - 1 WWW.PlanDeGraissage.ORG...
  • Page 3 INTRODUCTION 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 0 - 2 WWW.PlanDeGraissage.ORG...

  • Page 4: Introduction

    manual.

  • Page 5: Introduction

    INTRODUCTION LEONARDO 250 - 300 0.1.2. REFERENCE MANUALS Version 300 cc Version 250 cc SPARE PARTS CATALOGUES SPARE PARTS CATALOGUES aprilia part# (description) aprilia part# (description) 6572 OWNER’S MANUALS OWNER’S MANUALS aprilia part# (description) aprilia part# (description) 8104730 8104730 8104804...

  • Page 6: Abbreviations/Symbols/Conventions

    INTRODUCTION 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...
  • Page 7 INTRODUCTION LEONARDO 250 - 300 RIGHT SIDE = right side = 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 = flat head screw = Twin Spark Ignition...
  • Page 8 GENERAL INFORMATION LEONARDO 250 - 300 GENERAL INFORMATION 1 - 1 WWW.PlanDeGraissage.ORG...

  • Page 9: Table Of Contents

    GENERAL INFORMATION 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.

  • Page 10: Structure Of The Manual

    GENERAL INFORMATION 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.

  • Page 11: Safety Warnings

    GENERAL INFORMATION LEONARDO 250 - 300 1.1.2. SAFETY WARNINGS The following precautionary warnings are used throughout this manual in order to convey the following messages: Safety warning. This symbol appears, whether in the manual or on the vehicle itself, to indicate a personal injury hazard.

  • Page 12: General Rules

    GENERAL INFORMATION LEONARDO 250 - 300 1.2. GENERAL RULES 1.2.1. BASIC SAFETY RULES CARBON MONOXIDE Should it be necessary to perform some operations with the vehicle running, make sure to work outdoors or in a well- aerated room. Avoid starting the engine in closed or badly-ventilated rooms.
  • Page 13 GENERAL INFORMATION LEONARDO 250 - 300 COOLANT The coolant is composed of ethylene glycol that, under certain conditions, can become inflammable and send out invisible flames causing severe burns. DANGER Be careful not to spill the coolant on the red-hot parts of the engine and the exhaust system: it may catch fire and send out invisible flames.
  • Page 14 Never clean a bearing with compressed air. NOTE All bearings must rotate freely with no hardness or noise. Replace any bearings that do not meet these requirements. Use ORIGINAL aprilia SPARE PARTS only. Use the specified lubricants and consumables. Where possible, lubricate a part before assembly.

  • Page 15: Dangerous Elements

    GENERAL INFORMATION LEONARDO 250 - 300 1.3. DANGEROUS ELEMENTS 1.3.1. WARNINGS FUEL DANGER The fuel used to operate engines is highly flammable and becomes explosive under particular conditions. Refuelling and engine service should take place in a well-ventilated area with the engine stopped. Do not smoke when refuelling or in the proximity of sources of fuel vapours.
  • Page 16 GENERAL INFORMATION LEONARDO 250 - 300 BRAKE FLUID NOTE This vehicle is fitted with front and rear disc brakes. Each braking system is operated by an independent hydraulic circuit. The information provided below applies to both braking systems. DANGER Do not use the vehicle in case brakes are worn out or do not work properly! The brakes are the parts that most ensure your safety and for this reason they must always be perfectly working.
  • Page 17 GENERAL INFORMATION LEONARDO 250 - 300 COOLANT DANGER Coolant is toxic when ingested and is an irritant, contact with eyes or skin may cause irritation. In the event of contact with eyes, rinse repeatedly with abundant water and seek medical advice. In the event of ingestion, induce vomiting, rinse mouth and throat with abundant water and seek medical advice immediately.
  • Page 18 GENERAL INFORMATION LEONARDO 250 - 300 TYRES WARNING If tyres are excessively inflated, the vehicle will be hard and uneasy to ride, thus making you feel not at your ease. In addition the roadworthiness, mainly on wet surfaces and during cornering, will be impaired.

  • Page 19: Running-In

    GENERAL INFORMATION LEONARDO 250 - 300 1.4. RUNNING-IN 1.4.1. RUNNING-IN RECOMMENDATIONS The running-in of the engine is essential to ensure its duration and correct functioning. If possible, drive on hilly roads and/or roads with many bends, so that the engine, the suspensions and the brakes un- dergo a more effective running-in.

  • Page 20: Vehicle Identification

    GENERAL INFORMATION LEONARDO 250 - 300 1.5. VEHICLE IDENTIFICATION 1.5.1. POSITION OF THE SERIAL NUMBERS These numbers are necessary for the registration of the ve- hicle. IMPORTANT Do not alter the identification numbers if you do not want to incur severe penal and administrative sanctions;...

  • Page 21: Using Tools And Spare Parts

    Use original aprilia spare parts only to replace original components. Original aprilia spare parts are high-quality components designed and built expressly for aprilia motorcycles. CAUTION Using any parts OTHER THAN original aprilia parts may lead to loss of performance and damage. 1 - 14 WWW.PlanDeGraissage.ORG...

  • Page 22: Specifications

    GENERAL INFORMATION LEONARDO 250 - 300 1.7. SPECIFICATIONS 1.7.1. SPECIFICATIONS Description DIMENSIONS Max. length 1865 mm Max. length (rear mudguard extension included ) 1955 mm Max. width 770 mm Overall height (front part of the fairing included) 1410 mm Seat height...
  • Page 23 GENERAL INFORMATION LEONARDO 250 - 300 SUSPENSIONS Front Telescopic hydraulic fork Stroke 90 mm Rear Two hydraulic shock absorbers with compression and rebound damping, spring preload adjustment Wheel stroke 90 mm BRAKES Front Disc brake - Ø 220 mm - with hydraulic transmission Rear combined Disc brake - Ø...

  • Page 24: How To Apply The Decals

    GENERAL INFORMATION LEONARDO 250 - 300 1.7.2. HOW TO APPLY THE DECALS Whenever you remove any body parts: CAUTION Handle plastic painted components with care to avoid scraping or damaging them. Proceed with care. Do not damage the snap-on tabs and matching recesses.
  • Page 25 GENERAL INFORMATION LEONARDO 250 - 300 • Rub the spatula (1) across the decal surface pressing moderately until removing excess soap and water from under the decal. IMPORTANT: Take care not to lift the decal corners and edges in the process.

  • Page 26: Products

    GENERAL INFORMATION LEONARDO 250 - 300 1.8. PRODUCTS 1.8.1. TABLE OF LUBRICANTS LUBRICANT PRODUCT Engine oil RECOMMENDED: SUPERBIKE 4, SAE 5W – 40 or 4T FORMULA RACING, SAE 5W - 40. Alternatively, use brand name oil complying with or exceeding the CCMC G-4, A.P.I.

  • Page 27: Product Applications

    GENERAL INFORMATION LEONARDO 250 - 300 1.8.2. PRODUCT APPLICATIONS Use only the products specified below for motorcycle maintenance. These products have demonstrated suitability for all usage conditions specified by the manufacturer after long-time test- ing. IMPORTANT: The products for which a part number is given are available at request, (SEE TABLE).

  • Page 28: Tightening

    GENERAL INFORMATION LEONARDO 250 - 300 1.9. TIGHTENING 1.9.1. FASTENERS Check and tighten as required after the first 1000 km (621 mi) and every 6000 km (3728 mi) or 12 months afterwards. WARNING The fasteners reported in the chart must be tightened to the specified torque using a torque wrench ®...
  • Page 29 GENERAL INFORMATION LEONARDO 250 - 300 HNDLEBARS AND CONTROLS Handlebars –fork (safety) Handlebars – fork (clamp) Vibration-damping weight - handlebars Mirrors – handlebars ELECTRIC SYSTEM Coil – frame Control unit – helmet compartment Horn – frame Voltage adjuster – helmet compartment FUEL TANK Fuel tank –...
  • Page 30 PERIODIC MAINTENANCE LEONARDO 250 - 300 PERIODIC MAINTENANCE 2 - 1 WWW.PlanDeGraissage.ORG...
  • Page 31 PERIODIC MAINTENANCE LEONARDO 250 - 300 CONTENTS 2.1. PERIODIC MAINTENANCE ..........................3 2.1.1. INTRODUCTION............................ 3 2.1.2. PERIODIC MAINTENANCE CHART...................... 4 2.2. BATTERY ................................ 5 2.2.1. BATTERY............................... 5 2.3. SPARK PLUG..............................8 2.3.1. SPARK PLUG ............................8 2.4. AIR CLEANERS ............................10 2.4.1.

  • Page 32: Periodic Maintenance

    2.1.1. INTRODUCTION In order to preserve the motorcycle in sleek running order, aprilia recommends that you strictly observe the periodic main- tenance intervals recommended for the different components. Outlined in this section are the recommended procedures for the periodic maintenance of the key components of the mo- torcycle.

  • Page 33: Periodic Maintenance Chart

    PERIODIC MAINTENANCE LEONARDO 250 - 300 2.1.2. PERIODIC MAINTENANCE CHART After running-in Every 6000 km Every 12000 km Component [1000 km (625 mi)] (3750 mi) or 12 (7500 mi) or 24 months months Rear shock absorber Transmission cables and controls...

  • Page 34: Battery

    PERIODIC MAINTENANCE LEONARDO 250 - 300 2.2. BATTERY 2.2.1. BATTERY There are two types of batteries available in the market: batteries that require maintenance, fitted with cell plugs; maintenance-free batteries, which have no cell plugs as they do not need inspecting or topping-up.

  • Page 35: Battery

    PERIODIC MAINTENANCE LEONARDO 250 - 300 CHECKING AND CLEANING THE TERMINALS AND CLAMPS • Make sure that the ignition switch is set to " ". • Raise the seat. • Remove the battery cover. • Loosen and remove the two screws on battery cables.
  • Page 36 PERIODIC MAINTENANCE LEONARDO 250 - 300 RECHARGING THE BATTERY IMPORTANT You can tell that the battery is nearly flat when you hear a rattling sound from the starter relay when press- ing the starter button " ". IMPORTANT Do not remove the battery plugs or the battery may damage.

  • Page 37: Spark Plug

    PERIODIC MAINTENANCE LEONARDO 250 - 300 2.3. SPARK PLUG 2.3.1. SPARK PLUG Check the spark plug after the first 1,000 km (621 mi), and then every 6,000 km (3,728 m). Change it every 1,2000 km (7,456 mi). • Check the spark plug regularly, remove carbon de- posits and replace if necessary.
  • Page 38 PERIODIC MAINTENANCE LEONARDO 250 - 300 • Check the electrode gap with a wire feeler gauge. • Electrode gap should be 0.7 – 0.8 mm (0.027 – 0.031 in). If it needs adjusting, bend the earth elec- trode carefully. •...

  • Page 39: Air Cleaners

    PERIODIC MAINTENANCE LEONARDO 250 - 300 2.4. AIR CLEANERS 2.4.1. AIR CLEANER Clean the air cleaner every 6,000 km (3,728 mi) or 12 months, or more frequently if the vehicle is used on dusty or wet roads. • It is possible to clean the air cleaner partially after us- ing the vehicle on this kind of roads.

  • Page 40: Driving Belt Casing Air Cleaner

    PERIODIC MAINTENANCE LEONARDO 250 - 300 2.4.2. DRIVING BELT CASING AIR CLEANER WARNING Do not use petrol or inflammable solvents to wash the air cleaner, in order to avoid fires or explosions. Check the conditions of the belt casing air cleaner and clean it every 6000 km.

  • Page 41: Coolant

    PERIODIC MAINTENANCE LEONARDO 250 - 300 2.5. COOLANT 2.5.1. COOLANT CHECKING AND TOPPING UP COOLANT LEVEL • Check coolant level before each ride. Change coolant every 2 years. WARNING Check and top up coolant level when the engine is cold.
  • Page 42 PERIODIC MAINTENANCE LEONARDO 250 - 300 CHANGING THE COOLANT CAUTION Stop the engine and wait until the engine and the exhaust system have cooled down. DO NOT DISPOSE OF COOLANT IN THE ENVI- RONMENT • Position the vehicle on the stand.

  • Page 43: Brakes

    PERIODIC MAINTENANCE LEONARDO 250 - 300 2.6. BRAKES 2.6.1. BRAKES IMPORTANT The brakes are the parts that most ensure your safety and for this reason they must always be perfectly working. This vehicle is provided with front and rear hydraulic disc brakes.
  • Page 44 PERIODIC MAINTENANCE LEONARDO 250 - 300 CAUTION The topping up to the "MAX" level can be carried out only with new pads. The fluid level decreases pro- gressively with the pad wear. Do not top up to the "MAX" level with worn pads, since this may cause an outflow of liquid when the brake pads are changed.
  • Page 45 PERIODIC MAINTENANCE LEONARDO 250 - 300 Front brake pad (9). Rear brake pad (10). BLEEDING THE BRAKING SYSTEM The air, when present in the hydraulic circuit, absorbs most of the pressure exerted by the brake pump and therefore re- duces the effectiveness of the calliper action during the brak- ing.
  • Page 46 PERIODIC MAINTENANCE LEONARDO 250 - 300 CAUTION Do not dirt the pads or the disc with brake fluid. • Put the free end of the transparent pipe inside a con- tainer. • Slowly and thoroughly pull the brake lever for two or three times and do not release it.

  • Page 47: Engine Oil

    PERIODIC MAINTENANCE LEONARDO 250 - 300 2.7. ENGINE OIL 2.7.1. ENGINE OIL Change engine oil at regular intervals, see 2.1.2 (PERIODIC MAINTENANCE CHART). IMPORTANT Use the recommended oil only, see 1.8.1 (TA- BLE OF LUBRICANTS). Do not overfill (top up beyond the "Max" level).
  • Page 48 PERIODIC MAINTENANCE LEONARDO 250 - 300 ENGINE OIL AND FILTER CHANGE • Place the motorcycle on firm and level ground. • Place the motorcycle on the centre stand. WARNING Allow the engine and exhaust system to cool down before proceeding.

  • Page 49: The Transmission Oil

    PERIODIC MAINTENANCE LEONARDO 250 - 300 2.8. THE TRANSMISSION OIL 2.8.1. THE TRANSMISSION OIL CHECKING THE TRANSMISSION OIL LEVEL To check the transmission oil level, proceed as follows. • Drive for a few miles until the engine reaches the nor- mal running temperature, then stop it.

  • Page 50: Front End

    PERIODIC MAINTENANCE LEONARDO 250 - 300 2.9. FRONT END 2.9.1. FRONT END CHECKING THE STEERING Occasionally check the steering slack. To check the steering: • Position the vehicle on the centre stand. NOTE Prepare a support whose height should be: 185 mm the support base must measure 200 x 200 mm.
  • Page 51 PERIODIC MAINTENANCE LEONARDO 250 - 300 INSPECTING THE FRONT • With pulled front brake lever, push the fork repeatedly downwards. The stroke must be gentle and there must be no trace of oil on the rods. • Check the fastening of all the components and the functionality of the front and rear suspension joints.

  • Page 52: 2.10. Tail End

    PERIODIC MAINTENANCE LEONARDO 250 - 300 2.10. TAIL END 2.10.1. TAIL END CHECKING THE ENGINE FULCRUM AXIS Periodically check the slack existing between the engine pin bushings. To carry out this operation, proceed as follows: • Position the vehicle on the centre stand.

  • Page 53: 2.11. Accelerator Control

    PERIODIC MAINTENANCE LEONARDO 250 - 300 2.11. ACCELERATOR CONTROL 2.11.1. ACCELERATOR CONTROL IDLING ADJUSTMENT Adjust the idling every time it is irregular. To carry out this operation, proceed as follows: • Ride for a few miles until reaching the normal running temperature, then stop the engine.

  • Page 54: 2.12. Wheels/Tyres

    After repairing a tyre, have the wheels bal- anced. Use only tyres in the size suggested by aprilia. Do not install tyres with air tube on rims for tubeless tyres and viceversa. Make sure that the tyres always have their valve sealing caps on, to prevent them from suddenly going flat.
  • Page 55 LUBRICATION LEONARDO 250 - 300 LUBRICATION 3 - 1 WWW.PlanDeGraissage.ORG...
  • Page 56 LUBRICATION LEONARDO 250 - 300 CONTENTS 3.1. LUBRICATION..........................3 3.1.1. LUBRICATION ........................3 3 - 2 WWW.PlanDeGraissage.ORG...
  • Page 57 LUBRICATION LEONARDO 250 - 300 3.1. LUBRICATION 3.1.1. LUBRICATION The lubrication system is described in the engine workshop manual, see 0.1.2 (REFERENCE MANUALS). 3 - 3 WWW.PlanDeGraissage.ORG...
  • Page 58 FUEL SYSTEM LEONARDO 250 - 300 FUEL SYSTEM 4 - 1 WWW.PlanDeGraissage.ORG...
  • Page 59 FUEL SYSTEM LEONARDO 250 - 300 CONTENTS 4.1. FUEL TANK ..............................3 4.1.1. FUEL SYSTEM DIAGRAM ......................... 3 4.1.2. REMOVING THE FUEL TANK........................5 4.1.3. REMOVING THE PUMP UNIT........................6 4.2. AIR FILTER ..............................7 4.2.1. REMOVING THE AIR FILTER ........................7 4.2.2.

  • Page 60: Fuel Tank

    FUEL SYSTEM LEONARDO 250 - 300 4.1. FUEL TANK 4.1.1. FUEL SYSTEM DIAGRAM Key: Tank Fuel pump filter Fuel pump Fuel supply pipe Vacuum pipe Fuel level sensor Heater hosed Induction manifold 4 - 3 WWW.PlanDeGraissage.ORG...
  • Page 61 FUEL SYSTEM LEONARDO 250 - 300 TANK AND FUEL PUMP The fuel pump (3), positioned inside the fuel tank (1), is op- erated by the pulsating vacuum drawn from the induction manifold (8) through the vacuum pipe (5). The fuel, driven by the pump, flows into the fuel supply pipe (4) and reaches the carburettor.

  • Page 62: Removing The Fuel Tank

    FUEL SYSTEM LEONARDO 250 - 300 4.1.2. REMOVING THE FUEL TANK • Position the vehicle on the central stand. WARNING Wait until the engine and the exhaust silencer have completely cooled down. • Remove the footrest, see 7.1.5 (REMOVING THE FOOTPEG).

  • Page 63: Removing The Pump Unit

    FUEL SYSTEM LEONARDO 250 - 300 4.1.3. REMOVING THE PUMP UNIT • Remove the fuel tank, see 7.1.9 (REMOVING THE REAR-VIEW MIRRORS). WARNING Handle with care. Upon removal, take care not to damage the fuel gauge unit. • Rotate the fuel gauge unit (1) anticlockwise and extract it with care.

  • Page 64: Air Filter

    FUEL SYSTEM LEONARDO 250 - 300 4.2. AIR FILTER 4.2.1. REMOVING THE AIR FILTER REMOVAL • Position the vehicle on the centre stand. • Unscrew and remove the five screws (1). • Remove: filter case cover (2); flame trap grid (3);...

  • Page 65: Removing The Filter Box

    FUEL SYSTEM LEONARDO 250 - 300 4.2.2. REMOVING THE FILTER BOX • Release clip. • Remove blow-by pipe. • Loosen carburettor clip. • Release air filter box breather pipe. • Loosen and remove both retaining screws. • Remove filter box.

  • Page 66: Carburettor

    FUEL SYSTEM LEONARDO 250 - 300 4.3. CARBURETTOR 4.3.1. CARBURETTOR DIAGRAM 4 - 9 WWW.PlanDeGraissage.ORG...
  • Page 67 FUEL SYSTEM LEONARDO 250 - 300 Key: Float Complete membrane Screw Screw Metering rod stopper Grommet Gasket 10. Fuel inlet valve 11. Complete control valve 12. O-ring 13. Screw 14. Full-power jet 15. Idling jet 16. Plug 17. Screw 18. Spray nozzle 19.

  • Page 68: Removing The Carburettor

    FUEL SYSTEM LEONARDO 250 - 300 4.3.2. REMOVING THE CARBURETTOR • Position the vehicle on the stand. • Remove the air filter box, see 4.2.2 (REMOVING THE AIR FILTER BOX). • Remove the battery compartment, see 7.1.18 (RE- MOVING THE BATTERY COMPARTMENT).
  • Page 69 FUEL SYSTEM LEONARDO 250 - 300 • Disconnect the fuel delivery pipe (5) from the carburet- tor. • Completely unscrew the nut (6) that fixes the rigid bend of the accelerator cable (7). • Withdraw the rigid bend of the accelerator cable (7) from its seat.
  • Page 70 COOLING SYSTEM LEONARDO 250 - 300 COOLING SYSTEM 5 - 1 WWW.PlanDeGraissage.ORG...
  • Page 71 COOLING SYSTEM LEONARDO 250 - 300 CONTENTS 5.1. COOLING SYSTEM DIAGRAM....................3 5.1.1. COOLING SYSTEM DIAGRAM ...................3 5.2. RADIATOR ..........................4 5.2.1. REMOVING THE RADIATOR ....................4 5.2.2. REMOVING THE COOLING ELECTRIC FAN..............5 5.2.3. REMOVING THE COOLANT THERMAL SWITCH ...............6 5.2.4. REMOVING THE COOLANT THERMISTOR ...............7 5.3.

  • Page 72: Cooling System Diagram

    COOLING SYSTEM LEONARDO 250 - 300 5.1. COOLING SYSTEM DIAGRAM 5.1.1. COOLING SYSTEM DIAGRAM Key: Electric fan Return pipe Thermal switch Delivery pipe Expansion reservoir Expansion reservoir pipe – radiator Breather pipe Radiator Water temperature sensor Black arrow: indicates the heated fluid flowing to the radiator.

  • Page 73: 5.2. Radiator

    COOLING SYSTEM LEONARDO 250 - 300 5.2. RADIATOR 5.2.1. REMOVING THE RADIATOR • Drain the coolant completely, see 2.5 (CHANGING THE COOLANT). • Remove the front inner shield, see 7.1.6 (REMOVING THE FRONT INNER SHIELD). • Remove the headlight, see 7.2.7 (REMOVING THE HEADLIGHT).

  • Page 74: Removing The Cooling Electric Fan

    COOLING SYSTEM LEONARDO 250 - 300 5.2.2. REMOVING THE COOLING ELECTRIC FAN • Remove headlight, see 7.2.7 (REMOVING THE HEADLIGHT). • Disconnect the electric connector (1). • Unscrew and remove the three self-locking nuts (2) and take the washers. •...

  • Page 75: Removing The Coolant Thermal Switch

    COOLING SYSTEM LEONARDO 250 - 300 5.2.3. REMOVING THE COOLANT THERMAL SWITCH • Position the vehicle on the central stand. IMPORTANT Stop the engine and wait until the radiator has cooled down. • Remove the front inner shield, see 7.1.6 (REMOVING THE FRONT INNER SHIELD).

  • Page 76: Removing The Coolant Thermistor

    COOLING SYSTEM LEONARDO 250 - 300 5.2.4. REMOVING THE COOLANT THERMISTOR • Drain the coolant completely, see 2.5 (COOLANT). • Remove battery compartment, see 7.1.18 (REMOVING BATTERY COMPARTMENT) • Disconnect the electric connector (1). • Unscrew and remove the thermistor (2).

  • Page 77: 5.3. Coolant Temperature Sensor

    COOLING SYSTEM LEONARDO 250 - 300 5.3. COOLANT TEMPERATURE SENSOR 5.3.1. REMOVING COOLANT TEMPERATURE SEN- • Position the vehicle on the central stand. IMPORTANT Stop the engine and wait until the radiator has cooled down. • Remove the front inner shield, see 7.1.6 (REMOVING THE FRONT INNER SHIELD) •...

  • Page 78: 5.4. The Expansion Tank

    COOLING SYSTEM LEONARDO 250 - 300 5.4. THE EXPANSION TANK 5.4.1. REMOVING THE EXPANSION TANK • Position the vehicle on the central stand. • Remove the front inner shield, see 7.1.6 (REMOVING THE FRONT INNER SHIELD). WARNING DO NOT DISPOSE OF THE COOLANT IN THE ENVIRONMENT.
  • Page 79 ENGINE LEONARDO 250 - 300 ENGINE 6 - 1 WWW.PlanDeGraissage.ORG...
  • Page 80 ENGINE LEONARDO 250 - 300 CONTENTS 6.1. EXHAUST SYSTEM ............................3 6.1.1. REMOVING THE EXHAUST SYSTEM....................... 3 6.2. REMOVING AND INSTALLING THE ENGINE ....................4 6.2.1. REMOVING ENGINE FROM FRAME......................4 6.2.2. REFITTING ENGINE TO FRAME......................11 6 - 2...

  • Page 81: Exhaust System

    ENGINE LEONARDO 250 - 300 6.1. EXHAUST SYSTEM 6.1.1. REMOVING THE EXHAUST SYSTEM • Rise vehicle on centre stand. WARNING Wait until the engine and the exhaust silencer have completely cooled down • Loosen and remove the two nuts (1) from exhaust manifold.

  • Page 82: Removing And Installing The Engine

    ENGINE LEONARDO 250 - 300 6.2. REMOVING AND INSTALLING THE ENGINE 6.2.1. REMOVING ENGINE FROM FRAME • Remove tail guard, see 7.1.3 (REMOVING TAIL GUARD). • Remove rear mudguard, see 7.1.16 (REMOVING REAR MUDGUARD). • Remove the battery compartment, see 7.1.18 (RE- MOVING THE BATTERY COMPARTMENT).
  • Page 83 ENGINE LEONARDO 250 - 300 • Release clip on carburettor. • Release air filter box breather pipe. • Loosen and remove both retaining screws. • Remove filter box. • Remove accelerator cable. 6 - 5 WWW.PlanDeGraissage.ORG...
  • Page 84 ENGINE LEONARDO 250 - 300 • Remove clip. • Remove fuel pipe from carburettor and then block it off. • Remove clip. • Remove vacuum pipe from intake manifold. • Remove clip. • Remove secondary air pipe from secondary air filter.
  • Page 85 ENGINE LEONARDO 250 - 300 • Disconnect spark plug cap. • Disconnect the two generator connectors. • Remove both starter motor cables. • Disconnect earth cable. 6 - 7 WWW.PlanDeGraissage.ORG...
  • Page 86 ENGINE LEONARDO 250 - 300 • Disconnect thermistor connector. • Disconnect automatic starter connector. • Disconnect throttle position sensor motor connector. • Loosen and remove both bottom screws from rear shock absorbers. 6 - 8 WWW.PlanDeGraissage.ORG...
  • Page 87 ENGINE LEONARDO 250 - 300 • Place a stand under engine. • Working on both sides, loosen engine link rod top screw. • Loosen and remove nut. • Slide out pin. 6 - 9 WWW.PlanDeGraissage.ORG...
  • Page 88 ENGINE LEONARDO 250 - 300 • To remove engine, slide it out from behind. 6 - 10 WWW.PlanDeGraissage.ORG...

  • Page 89: Refitting Engine To Frame

    ENGINE LEONARDO 250 - 300 6.2.2. REFITTING ENGINE TO FRAME • Fit the engine to the frame. • Raise engine until holes are aligned. • Install pin. • Tighten nut. • Working on both sides, tighten engine link rod top screw.
  • Page 90 ENGINE LEONARDO 250 - 300 • Refit rear shock absorbers. • Tighten screws on both rear shock absorbers. • Connect throttle position sensor motor connector. • Connect automatic starter connector. 6 - 12 WWW.PlanDeGraissage.ORG...
  • Page 91 ENGINE LEONARDO 250 - 300 • Connect thermistor connector. • Re-route earth cable. • Re-route both starter motor cables. • Connect the two generator connectors. 6 - 13 WWW.PlanDeGraissage.ORG...
  • Page 92 ENGINE LEONARDO 250 - 300 • Refit spark plug cap. • Refit brake callipers into its seating. • Tighten the two screws. • Reconnect pipe to secondary air filter. • Secure pipe with a new clip. • Re-route vacuum pipe inside intake manifold.
  • Page 93 ENGINE LEONARDO 250 - 300 • Refit fuel pipe inside carburettor. • Secure pipe with clip. • Reconnect accelerator cable. • Adjust clearance, see 2.11 (ACCELERATOR). • Refit air filter box hose to carburettor. • Secure it to carburettor with clip.
  • Page 94 ENGINE LEONARDO 250 - 300 • Refit filter box breather pipe into its seating. • Re-connect the blow-by pipe to the air filter box. • Secure pipe with a new clip. • Refit cooling pipe to pump. • Secure pipe with clip.
  • Page 95 ENGINE LEONARDO 250 - 300 • Refit tail guard, see 7.1.3 (REMOVING TAIL GUARD). • Refit rear mudguard, see 7.1.16 (REMOVING REAR MUDGUARD). • Refit the battery compartment, see 7.1.18 (REMOVING THE BATTERY COMPARTMENT). • Fill the cooling system, see 2.5 (COOLANT).
  • Page 96 CYCLE PARTS LEONARDO 250 - 300 CYCLE PARTS 7 - 1 WWW.PlanDeGraissage.ORG...
  • Page 97 REMOVING THE REAR LIGHT ......................34 7.2.8. REMOVING THE NUMBER PLATE BULB ..................35 7.2.9. REMOVING THE COIL ........................36 7.2.10. REMOVING THE SERVICE WARNING LIGHT CONTROL UNIT (FOR LEONARDO 250 ONLY)..37 7.2.11. REMOVING THE IGNITION SWITCH/STEERING LOCK..............38 7.3. CONTROLS..............................39 7.3.1.
  • Page 98 CYCLE PARTS LEONARDO 250 - 300 7.10.5. CHECKING THE COMPONENTS ......................70 7.11. REAR SUSPENSION .............................71 7.11.1. REMOVING THE SHOCK ABSORBER....................71 7.11.2. REMOVING LINKAGES........................72 7.11.3. REASSEMBLING LINKAGES.......................73 7 - 3 WWW.PlanDeGraissage.ORG...

  • Page 99: Body

    CYCLE PARTS LEONARDO 250 - 300 7.1. BODY 7.1.1. REMOVING THE SADDLE • Position the vehicle on the central stand. • Lift the saddle. • Unscrew and remove the four screws (1). • Remove the saddle. 7 - 4 WWW.PlanDeGraissage.ORG...

  • Page 100: Removing The Rear Grab Rail

    CYCLE PARTS LEONARDO 250 - 300 7.1.2. REMOVING THE REAR GRAB RAIL • Remove the four screws (1). • Remove grab rail cover. • Loosen and remove the four screws(2). • Remove rear grab rail. 7 - 5 WWW.PlanDeGraissage.ORG...

  • Page 101: Removing The Rear Part Of The Fairing

    CYCLE PARTS LEONARDO 250 - 300 7.1.3. REMOVING THE REAR PART OF THE FAIRING • Remove rear grab rail, see 7.1.2 (REMOVING THE REAR GRAB RAIL). • Remove side inspection covers, see 7.1.4 (REMOV- ING RIGHT AND LEFT INSPECTION COVERS).
  • Page 102 CYCLE PARTS LEONARDO 250 - 300 • Move tail guard aside and disconnect connector. • Remove the rear part of the fairing. 7 - 7 WWW.PlanDeGraissage.ORG...
  • Page 103 CYCLE PARTS LEONARDO 250 - 300 7.1.4. REMOVING RIGHT AND LEFT INSPECTION COVERS NOTE the following operations refer to a single inspection cover, but apply to both of them. • Remove rubber footrest mat. • Loosen and remove the screw.

  • Page 104: Removing Right And Left Inspection Covers

    CYCLE PARTS LEONARDO 250 - 300 7.1.5. REMOVING THE FOOTPEGS • Remove right and left inspection covers, see 7.1.4 (REMOVING RIGHT AND LEFT INSPECTION COV- ERS). • Working on both sides, loosen and remove the seven screws (1-2). • Raise fuel filler cap flap.

  • Page 105: Removing The Front Inner Shield

    CYCLE PARTS LEONARDO 250 - 300 7.1.6. REMOVING THE FRONT INNER SHIELD • Remove the outer front shield, see 7.1.7 (REMOVING THE FRONT OUTER SHIELD. • Remove the two bumpers, see 7.1.10 (REMOVING THE BUMPERS). • Loosen and remove the two screws (1).
  • Page 106 CYCLE PARTS LEONARDO 250 - 300 • Remove rubber footrest mats. • Working on both sides, loosen and remove screw (5). • Working on both sides, loosen and remove screw. • Working on both sides, loosen and remove screw. •...

  • Page 107: Removing The Front Outer Shield

    CYCLE PARTS LEONARDO 250 - 300 7.1.7. REMOVING THE FRONT OUTER SHIELD • Position the vehicle on the central stand on a lifting platform, with the front wheel protruding from the plat- form edge. WARNING Put a proper support under the vehicle, in order to prevent it from falling down.

  • Page 108: Removing The Lower Shield

    CYCLE PARTS LEONARDO 250 - 300 7.1.8. REMOVING THE LOWER SHIELD • Remove passenger footpegs, see 7.4.4 (REMOVING PASSENGER FOOTPEGS). • Position the vehicle on the central stand. • Working on both sides, remove the footrest mat. • Working on both sides, unscrew and remove the four screws (1).
  • Page 109 CYCLE PARTS LEONARDO 250 - 300 • Unscrew and remove the four screws (3). WARNING Proceed with care. Do not damage the tangs and/or the relevant seatings. Handle the painted components with care and avoid scraping or damaging them. •...

  • Page 110: Removing The

    CYCLE PARTS LEONARDO 250 - 300 7.1.9. REMOVING THE FRONT COVER • Position the vehicle on the central stand. • Unscrew and remove the two rear screws (1). WARNING Proceed with care. Do not damage the tangs and/or the relevant seatings. Handle the painted components with care and avoid scraping or damaging them.

  • Page 111: Removing The Bumpers

    CYCLE PARTS LEONARDO 250 - 300 7.1.10. REMOVING THE BUMPERS NOTE the following operations refer to one bumper, but they apply to both of them. • Unscrew and remove the three screws (1). • Remove bumper. 7 - 16 WWW.PlanDeGraissage.ORG...

  • Page 112: Removing The Windshield

    CYCLE PARTS LEONARDO 250 - 300 7.1.11. REMOVING THE WINDSHIELD • Unscrew and remove the four screws (1). • Remove the windshield (2). 7 - 17 WWW.PlanDeGraissage.ORG...

  • Page 113: Removing The Front Fairing

    CYCLE PARTS LEONARDO 250 - 300 7.1.12. REMOVING THE FRONT FAIRING • Remove the windshield, see 7.1.11 (REMOVING THE WINDSHIELD). • Unscrew and remove the five screws (1). • Remove the front fairing (2). 7 - 18 WWW.PlanDeGraissage.ORG...

  • Page 114: Removing The Front Handlebar Cover

    CYCLE PARTS LEONARDO 250 - 300 7.1.13. REMOVING THE FRONT HANDLEBAR COVER • Remove the front fairing, see 7.1.12 (REMOVING THE FRONT FAIRING). • Working on both sides, unscrew and remove the two screws (1) and remove mounting bracket (2).

  • Page 115: Removing The Rear Handlebar Cover

    CYCLE PARTS LEONARDO 250 - 300 7.1.14. REMOVING THE REAR HANDLEBAR COVER • Remove front handlebar cover, see 7.1.13 (REMOV- ING THE FRONT HANDLEBAR COVER). • Unscrew and remove the three screws (1). • Unscrew and remove the three screws (2).

  • Page 116: Removing The Front Mudguard

    CYCLE PARTS LEONARDO 250 - 300 7.1.15. REMOVING THE FRONT MUDGUARD • Position the vehicle on the central stand. • Working on both sides, unscrew and remove the two screws (1). • Remove the mudguard (2) by withdrawing it from the front part of the vehicle.

  • Page 117: Removing The Rear Mudguard

    CYCLE PARTS LEONARDO 250 - 300 7.1.16. REMOVING THE REAR MUDGUARD • Unscrew and remove side screw. • Unscrew and remove top screw. • Remove rear mudguard. 7 - 22 WWW.PlanDeGraissage.ORG...

  • Page 118: Removing The Crash Helmet Compartment

    Unscrew and remove the five screws (1), and then re- move: Starting relay (2); Control unit (3); Voltage regulator (4); Service control unit (for Leonardo 250, only) (5). • Unscrew and remove the two screws (6) and remove filter (7). •...

  • Page 119: Removing The Battery Compartment

    CYCLE PARTS LEONARDO 250 - 300 7.1.18. REMOVING THE BATTERY COMPARTMENT • Remove battery, see 7.2.1 (REMOVING THE BAT- TERY). • Release fuses from their seating. • Disconnect service warning light reset connector (for Leonardo 250, only). • Unscrew and remove the four screws i (1).

  • Page 120: Electric Parts

    CYCLE PARTS LEONARDO 250 - 300 7.2. ELECTRIC PARTS 7.2.1. REMOVING THE BATTERY • Raise saddle. • Unscrew and remove the two screws. • Remove battery cover. • Disconnect battery cables (always disconnect positive cable first, and then negative one).
  • Page 121 CYCLE PARTS LEONARDO 250 - 300 • Slide breather pipe out of battery. • Remove battery. 7 - 26 WWW.PlanDeGraissage.ORG...

  • Page 122: Removing The Control Unit

    CYCLE PARTS LEONARDO 250 - 300 7.2.2. REMOVING THE CONTROL UNIT • Remove tail guard, see 7.1.3 (REMOVING TAIL GUARD). • Disconnect connector (1). • Unscrew and remove the two screws (2) and remove the control unit (3). 7 - 27...

  • Page 123: Removing The Voltage Regulator

    CYCLE PARTS LEONARDO 250 - 300 7.2.3. REMOVING THE VOLTAGE REGULATOR • Remove tail guard, see 7.1.3 (REMOVING TAIL GUARD). • Disconnect connectors (1). • Unscrew and remove the two screws (2) and remove voltage regulator (3). 7 - 28...

  • Page 124: Removing The Dashboard

    CYCLE PARTS LEONARDO 250 - 300 7.2.4. REMOVING THE DASHBOARD • Remove the rear handlebar cover, see7.1.14 (REMOV- ING THE REAR HANDLEBAR COVER). • Disconnect the speedometer/odometer cable (1) from the dashboard. • Disconnect the two electric connectors (3-4). •...

  • Page 125: Removing The Headlight

    CYCLE PARTS LEONARDO 250 - 300 7.2.5. REMOVING THE HEADLIGHT • Remove the front inner shield, see 7.1.6 (REMOVING THE FRONT INNER SHIELD). • Unscrew and remove the two screws (1) complete with washer. • Remove the air deflector. •...
  • Page 126 CYCLE PARTS LEONARDO 250 - 300 • Withdraw the headlight from the front part of the vehi- cle and remove it. 7 - 31 WWW.PlanDeGraissage.ORG...

  • Page 127: Removing The Front Direction Indicators

    CYCLE PARTS LEONARDO 250 - 300 7.2.6. REMOVING THE FRONT DIRECTION INDICA- TORS NOTE the following operations refer to one direction indica- tor, but they apply to both of them. • Position the vehicle on the central stand. • Unscrew and remove the screw.
  • Page 128 CYCLE PARTS LEONARDO 250 - 300 • Remove the indicator complete with bulb (9). 7 - 33 WWW.PlanDeGraissage.ORG...

  • Page 129: Removing The Rear Light

    CYCLE PARTS LEONARDO 250 - 300 7.2.7. REMOVING THE REAR LIGHT • Remove the rear part of the fairing, see 7.1.3 (REMOV- ING THE REAR PART OF THE FAIRING). • Remove the plate number light, see 7.2.8 (REMOVING THE NUMBER PLATE LIGHT).

  • Page 130: Removing The Number Plate Bulb

    CYCLE PARTS LEONARDO 250 - 300 7.2.8. REMOVING THE NUMBER PLATE BULB • Unscrew and remove screw (1). • Remove the number plate light (2). • Remove the number plate bulb (3). 7 - 35 WWW.PlanDeGraissage.ORG...

  • Page 131: Removing The Coil

    CYCLE PARTS LEONARDO 250 - 300 7.2.9. REMOVING THE COIL • Remove the rear part of fairing, see 7.1.3 (REMOVING THE REAR PART OF FAIRING). • Disconnect connectors (1). • Unscrew and remove the two screws (2), and remove coil (3).

  • Page 132: Removing The Service Warning Light Control Unit (For Leonardo 250 Only)

    CYCLE PARTS LEONARDO 250 - 300 7.2.10. REMOVING THE SERVICE WARNING LIGHT CONTROL UNIT (FOR LEONARDO 250 ONLY) • Remove the rear part of fairing, see 7.1.3 (REMOVING THE REAR PART OF FAIRING). • Disconnect connector (1). • Unscrew and remove screw (2), and remove service warning light control unit (3).

  • Page 133: Removing The Ignition Switch/Steering Lock

    CYCLE PARTS LEONARDO 250 - 300 7.2.11. REMOVING THE IGNITION SWITCH/STEERING LOCK • Remove the front inner shield, see 7.1.4 (REMOVING THE FRONT INNER SHIELD). • Disconnect the electric connector (1). • Unscrew and remove the two screws (2). •...

  • Page 134: Controls

    CYCLE PARTS LEONARDO 250 - 300 7.3. CONTROLS 7.3.1. REMOVING THE THROTTLE CONTROL • Remove rear handlebar cover, see7.1.14 (REMOVING THE REAR HANDLEBAR COVER). • Unscrew and remove screw (1). • Remove balancing weight (2). • Unscrew and remove the two screws (3).

  • Page 135: Removing The Rear Brake Master Cylinder

    CYCLE PARTS LEONARDO 250 - 300 7.3.2. REMOVING THE REAR BRAKE MASTER CYL- INDER • Remove rear handlebar cover, see 7.1.14 (REMOVING THE REAR HANDLEBAR COVER). • Unscrew the two screws (1). • Remove brace (2). • Remove rear brake master cylinder, but do not discon- nect it from brake line.

  • Page 136: Removing The Left Handgrip

    CYCLE PARTS LEONARDO 250 - 300 7.3.3. REMOVING THE LEFT HANDGRIP • Unscrew and remove screw (1). • Remove balancing weight (2). • Remove handgrip (3). 7 - 41 WWW.PlanDeGraissage.ORG...

  • Page 137: Removing The Front Brake Master Cylinder

    CYCLE PARTS LEONARDO 250 - 300 7.3.4. REMOVING THE FRONT BRAKE MASTER CYLINDER • Remove rear handlebar cover, see 7.1.14 (REMOVING THE REAR HANDLEBAR COVER). • Unscrew the two screws (1). • Remove brace (2). • Remove front brake master cylinder, but do not dis- connect it from brake line.

  • Page 138: Frame

    CYCLE PARTS LEONARDO 250 - 300 7.4. FRAME 7.4.1. REMOVING HANDLEBARS • Remove the instrument cluster, see 7.2.4 (REMOVING THE INSTRUMENT CLUSTER). • Remove the throttle control, see 7.3.1 (REMOVING THE THROTTLE CONTROL). • Remove rear brake master cylinder, see 7.3.2 (RE- MOVING REAR BRAKE MASTER CYLINDER).

  • Page 139: Removing The Side Stand

    CYCLE PARTS LEONARDO 250 - 300 7.4.2. REMOVING THE SIDE STAND • Position the vehicle on the central stand. • Remove the lower left shield, see 7.1.8 (REMOVING THE LOWER SHIELD). WARNING Work with the side stand in rest position.

  • Page 140: Removing The Central Stand

    CYCLE PARTS LEONARDO 250 - 300 7.4.3. REMOVING THE CENTRAL STAND • Position the vehicle on the side stand. WARNING Wait until the engine and the exhaust silencer have completely cooled down. • Working on both sides, disconnect the spring (1) from the stand hook (2).

  • Page 141: Removing Passenger Footrest

    CYCLE PARTS LEONARDO 250 - 300 7.4.4. REMOVING PASSENGER FOOTREST NOTE the following operations refer to a single passenger footrest, but apply to both of them. • Position the vehicle on the central stand. • Rotate the passenger footrest (1) in the position of use.

  • Page 142: Front Wheel

    CYCLE PARTS LEONARDO 250 - 300 7.5. FRONT WHEEL 7.5.1. FRONT WHEEL DIAGRAM Key: Wheel pin Speedometer control Bearing Inner spacer ring Complete wheel Outer spacer ring Washer 7 - 47 WWW.PlanDeGraissage.ORG...

  • Page 143: Removal

    CYCLE PARTS LEONARDO 250 - 300 7.5.2. REMOVAL WARNING While disassembling/reassembling the wheel, take care not to damage the brake pipe, the disc and the pads. • Position the vehicle on the central stand. WARNING Place a support under the vehicle, so that the front wheel has enough space to move and the vehicle cannot fall down.

  • Page 144: Changing The Bearings

    CYCLE PARTS LEONARDO 250 - 300 7.5.3. CHANGING THE BEARINGS WARNING The bearings must be checked and if necessary changed every time they are removed. • Clean the two sides of the hub with a cloth. Disassembly Work on the left side of the vehicle: •...

  • Page 145: Checking Front Wheel Parts

    CYCLE PARTS LEONARDO 250 - 300 7.5.4. CHECKING FRONT WHEEL PARTS WARNING Check the integrity of all the components and in particular those indicated below. Bearings • Manually rotate the inner ring (1), which should rotate without jamming and/or noise. There should be no ax- ial slacks.

  • Page 146: Rear Wheel

    CYCLE PARTS LEONARDO 250 - 300 7.6. REAR WHEEL 7.6.1. REAR WHEEL DIAGRAM Key: Brake callipers – muffler mount Dust seal Spacer Brake disc screw Brake disc Rear rim Rear wheel washer 7 - 51 WWW.PlanDeGraissage.ORG...

  • Page 147: Removing The Rear Wheel

    CYCLE PARTS LEONARDO 250 - 300 7.6.2. REMOVING THE REAR WHEEL WARNING Wait until the engine and the exhaust silencer have completely cooled down. While disas- sembling/ reassembling the wheel, be careful not to damage the brake pipe, the disc and the pads.

  • Page 148: Front Brake

    CYCLE PARTS LEONARDO 250 - 300 7.7. FRONT BRAKE 7.7.1. FRONT BRAKE DIAGRAM Key: Brake control lever Brake fluid pump/tank Brake fluid pipe Bleed valve Pipe fitting screw Brake caliper Brake pads Brake disc 7 - 53 WWW.PlanDeGraissage.ORG...

  • Page 149: Replacing The Front Brake Pads

    CYCLE PARTS LEONARDO 250 - 300 7.7.2. REPLACING THE FRONT BRAKE PADS • Remove the calliper, • Unscrew and remove the central screw (1). • Extract the retainer (2). • Remove the two retaining pins (3). • Extract the brake pads(4).

  • Page 150: Checking Front Brake Disc

    CYCLE PARTS LEONARDO 250 - 300 7.7.3. CHECKING FRONT BRAKE DISC WARNING These operations must be performed with the brake disc installed on the wheel. • Carry out a visual check of the brake disc surface. If scratches or signs of deterioration are visible, change the disc, see 7.4.3 (REMOVING THE FONT BRAKE...

  • Page 151: Removing The Front Brake Disc

    CYCLE PARTS LEONARDO 250 - 300 7.7.4. REMOVING THE FRONT BRAKE DISC • Remove the front wheel, see 7.5.2 (REMOVING THE FRONT WHEEL). • Unscrew and remove the five brake disc screws (1). IMPORTANT Screw all the screws manually and tighten...

  • Page 152: Rear Brake

    CYCLE PARTS LEONARDO 250 - 300 7.8. REAR BRAKE 7.8.1. REAR BRAKE DIAGRAM Brake control lever Brake fluid pump/tank Brake fluid pipe Bleed valve Pipe fitting screw Brake calliper Pad pin Stop ring Brake pads 10. Antivibration plates 11. Pad spring 12.

  • Page 153: Replacing The Rear Brake Pads

    CYCLE PARTS LEONARDO 250 - 300 7.8.2. REPLACING THE REAR BRAKE PADS • Remove the rear brake caliper, (REMOVING THE REAR WHEEL). • Remove the circlip (1). • Remove the spindle (2). • Remove the spring (3). CAUTION The spring (3) is stamped with an arrow which must always be oriented in the direction of travel of the motorcycle..

  • Page 154: Checking The Rear Brake Disc

    CYCLE PARTS LEONARDO 250 - 300 7.8.3. CHECKING THE REAR BRAKE DISC CAUTION These operations must be performed with the brake disc installed on the wheel. • Carry out a visual check of the brake disc surface. If scratches or signs of deterioration are visible, change the disc, see 7.5.3 (REMOVING THE REAR BRAKE...

  • Page 155: Removing The Rear Brake Disc

    CYCLE PARTS LEONARDO 250 - 300 7.8.4. REMOVING THE REAR BRAKE DISC • Remove the front wheel, see 7.5.2 (REMOVING THE REAR WHEEL). • Unscrew and remove the five brake disc screws (1). IMPORTANT Screw all the screws manually and tighten...

  • Page 156: Steering

    CYCLE PARTS LEONARDO 250 - 300 7.9. STEERING 7.9.1. STEERING DIAGRAM Key: Cover Rubber seal Check nut Adjusting nut Upper rotating seat Upper bearing balls Upper fixed seat Lower fixed seat Lower bearing balls 10. Lower rotating seat 7 - 61...

  • Page 157: Removing The Steering Stem

    CYCLE PARTS LEONARDO 250 - 300 7.9.2. REMOVING THE STEERING STEM • Remove the lower shield, see 7.1.8 (REMOVING THE LOWER SHIELD). • Position the vehicle on the central stand on a lifting platform, with the front wheel protruding from the plat- form edge.
  • Page 158 CYCLE PARTS LEONARDO 250 - 300 • Remove the lower rotating seat (11) and the balls (12) of the lower bearing. • Remove the grease from all the bearing components, including the fixed seats (13) and (14). • Check the conditions of the components and if they are worn change them.

  • Page 159: Checking Steering Components

    CYCLE PARTS LEONARDO 250 - 300 7.9.3. CHECKING STEERING COMPONENTS CAUTION Check the integrity of the components. • Make sure that the area in contact with the balls (1) (on the rotating seat (2) and on the fixed seat (3)) is neither damaged, nor excessively worn out.

  • Page 160: 7.10. Front Fork

    CYCLE PARTS LEONARDO 250 - 300 7.10. FRONT FORK 7.10.1. FORNT FORK DIAGRAM Key: Leg cap Snap ring O-ring Plug Spring Segment Right damper rod Countersrping Legs retaining screws 10. Washer 11. Fork bottom with steering stem 12. Left damper rod 13.

  • Page 161: Checking The Oil Level

    CYCLE PARTS LEONARDO 250 - 300 7.10.2. CHECKING THE OIL LEVEL If the fork stroke is excessive, it is necessary to check the fork oil level. • Remove the front inner shield, see 7.1.6 (REMOVING THE FRONT INNER SHIELD). WARNING...

  • Page 162: Removing Fork Leg/Slider Assembly

    CYCLE PARTS LEONARDO 250 - 300 7.10.3. REMOVING FORK LEG/SLIDER ASSEMBLY IMPORTANT the following operations refer to a single fork leg/slider assembly, but apply to both of them. • Position the vehicle on the stand. CAUTION Place a proper support under the vehicle, in or- der to prevent it from falling down.

  • Page 163: Disassembling The Fork Leg/Slider Unit

    CYCLE PARTS LEONARDO 250 - 300 7.10.4. DISASSEMBLING THE FORK LEG/SLIDER UNIT NOTE the following operations refer to a single fork leg/slider assembly, but apply to both of them. • For the disassembly of the rubber cap (1), snap ring (2), seal plug (3) complete with “GACO”...
  • Page 164 CYCLE PARTS LEONARDO 250 - 300 • Take the bottom buffer (11) and the counterspring (12) by rotating the slider (10). • Remove the dust seal (13). • Remove the retaining ring (seeger) (14). • Remove the seal (15). •...

  • Page 165: Checking The Components

    CYCLE PARTS LEONARDO 250 - 300 7.10.5. CHECKING THE COMPONENTS Tube • Check the sliding surface, that must be neither lined, nor scratched. Slight lines can be eliminated by sand- ing the surface with wet sandpaper (grain 1). If the lines are deep, change the tube.

  • Page 166: 7.11. Rear Suspension

    CYCLE PARTS LEONARDO 250 - 300 7.11. REAR SUSPENSION 7.11.1. REMOVING THE SHOCK ABSORBER • Raise vehicle on centre stand. WARNING Wait until the engine and the exhaust silencer have completely cooled down. IMPORTANT Remove the shock absorbers one by one. To keep the vehicle in its position, always leave one shock ab- sorber installed on the vehicle.

  • Page 167: Removing Linkages

    CYCLE PARTS LEONARDO 250 - 300 7.11.2. REMOVING LINKAGES • Raise vehicle on centre stand on a on a lifting platform. • Secure front wheel to platform. • Remove the rear part of fairing, see 7.1.3 (REMOVING THE REAR PART OF THE FAIRING).

  • Page 168: Reassembling Linkages

    CYCLE PARTS LEONARDO 250 - 300 7.11.3. REASSEMBLING LINKAGES • Raise vehicle on centre stand on a on a lifting platform. • Secure front wheel to platform. • Position a proper support under the vehicle. • Refit linkages to engine.
  • Page 169 ELECTRICAL SYSTEM LEONARDO 250 - 300 ELECTRICAL SYSTEM 8 - 1 WWW.PlanDeGraissage.ORG...
  • Page 170 ELECTRICAL SYSTEM LEONARDO 250 - 300 CONTENTS 8.1. ARRANGEMENT OF ELECTRICAL PARTS ................3 8.1.1. ELECTRICAL PARTS......................3 8.2. ELECTRICAL SYSTEM DIAGRAM ....................10 8.2.1. ELECTRICAL SYSTEM DIAGRAM..................10 8 - 2 WWW.PlanDeGraissage.ORG...
  • Page 171 ELECTRICAL SYSTEM LEONARDO 250 - 300 8.1. ARRANGEMENT OF ELECTRICAL PARTS 8.1.1. ELECTRICAL PARTS 8 - 3 WWW.PlanDeGraissage.ORG...
  • Page 172 ELECTRICAL SYSTEM LEONARDO 250 - 300 1 Electric fan thermal switch NIPPON THERMOSTAT ON 98 +/- 3°C (37.4°F), OFF 92 +/- 3°C (37.4°F) 2 Electric fan 3 Flasher DENSO 12V 10W+10W 4 Battery 12 V - 12 Ah 8 - 4...
  • Page 173 ELECTRICAL SYSTEM LEONARDO 250 - 300 5 Fuses 7,5A (A) fuse: From the ignition switch to: ignition. 15A (B) fuse: From the ignition switch to: all light loads and horn. 20A (C) fuse: From the battery to: ignition switch, voltage regulator, elec- tric fan.
  • Page 174 LEONARDO 250 - 300 9 Fuel level sensor Float position 4-10 ohm DOWN 90-100 ohm 10 Service warning light control unit (for Leonardo 250, only) ITI (ECIE) 11 Voltage regulator (SH532B12) Recharge voltage: Measured voltage (at 5000 RPM) > 0.2 V Open-circuit voltage across terminals >...
  • Page 175 ELECTRICAL SYSTEM LEONARDO 250 - 300 13 Start relay 12 V / 100 A 14 Horn CEB 12V 4A 15 Automatic starter thermal switch NIPPON THERMOSTAT ON 75 +/- 3°C (37.4°F), OFF 70 +/- 3°C (37.4°F) 16 Headlight Low/high beams: 12 V - 35 / 35 W...
  • Page 176 ELECTRICAL SYSTEM LEONARDO 250 - 300 17 Front direction indicators Direction indicators light: 12 V - 10 W 18 Ignition switch-steering lock 19 Coil (MORIC) primary resistance: 3.6 – 4.8 ohm at 20°C (68°F) secondary resistance 10.7 – 14.5 K at 20°C (68°F) 20 Water temperature sensor 80°C (176°F)
  • Page 177 ELECTRICAL SYSTEM LEONARDO 250 - 300 21 Automatic starter 16 – 24 ohm at 20°C (68°F) 22 Generator 12 V - 200 W Stator coil resistance: 0.8 – 1 ohm at 20°C (68°F) 8 - 9 WWW.PlanDeGraissage.ORG...
  • Page 178 ELECTRICAL SYSTEM LEONARDO 250 - 300 8.2. ELECTRICAL SYSTEM DIAGRAM 8.2.1. ELECTRICAL SYSTEM DIAGRAM Leonardo 250 8 - 10 WWW.PlanDeGraissage.ORG...
  • Page 179 ELECTRICAL SYSTEM LEONARDO 250 - 300 Key: Generator Ignition coil Starter Voltage regulator Fuses Battery Start relay Front stoplight switch Rear stoplight switch 10. Coolant temperature thermistor 11. Engine oil change warning light disconnection push but- 12. Right direction indicator warning light 13.
  • Page 180 ELECTRICAL SYSTEM LEONARDO 250 - 300 Leonardo 300 8 - 12 WWW.PlanDeGraissage.ORG...
  • Page 181 ELECTRICAL SYSTEM LEONARDO 250 - 300 Key: Generator Ignition coil Starter Voltage regulator Fuses Battery Start relay Front stoplight switch Rear stoplight switch 10. Coolant temperature thermistor 11. Engine oil change warning light disconnection push button 12. Right direction indicator warning light 13.
  • Page 182 G.Galilei, 1 30033 Noale (VE) Italy tel. +39 041.5829111 fax +39 041.5829190 www.aprilia.com www.serviceaprilia.com WWW.PlanDeGraissage.ORG...

This manual is also suitable for:

Leonardo 300

Table of Contents