074 2 ATLANTIC 500 11/2002-00 8140633 workshopmanual
LIST OF SECTIONS Introduction This manual contains information on how to perform the usual vehicle service procedures. This manual does not describe all of the procedures necessary to repair and service the vehicle in detail. This publication is intended for use by aprilia dealers and their trained, experienced mechanics.
Atlantic 500 CONTENTS Chapter 1 SAFETY WARNINGS ............................................................................................................................. 1-2 PRECAUTIONS AND GENERAL INFORMATION ................................................................................. 1-2 REFITTING COMPONENTS ................................................................................................................. 1-3 USING THE MANUAL .......................................................
Atlantic 500 Chapter 3 ENGINE COMPONENTS THAT CAN BE REMOVED WITHOUT REMOVING THE ENGINE .............. 3-2 REMOVING THE ENGINE FROM THE FRAME ................................................................................... 3-3 Chapter 4 FUEL PUMP AND TANK ........................................................................................................................ 4-2 EMS FUEL INJECTION SYSTEM....................................................................................................
Atlantic 500 FUEL LEVEL ........................................................................................................................................ 6-22 CHECKING THE DASHBOARD .......................................................................................................... 6-22 CHECKING THE FUEL LEVEL SENSOR ............................................................................................ 6-22 LIGHTING AND SOUND SIGNAL SYSTEM ................................................
Atlantic 500 REMOVING THE COMPLETE DASHBOARD ..................................................................................... 7-15 REMOVING THE FRONT FAIRING ..................................................................................................... 7-16 REMOVING THE DASHBOARD PANEL ............................................................................................. 7-16 REMOVING THE COMPLETE LIGHT UNIT ................................................................................
Atlantic 500 6 Release 00 2002-09
General information Atlantic 500 1 General information chap.
General information Atlantic 500 SAFETY WARNINGS The following precautionary warnings are used throughout this manual in order to convey the following messages: Safety warning. When you find this symbol on the vehicle or in the manual, be careful to the potential risk of personal injury.
General information Atlantic 500 REFITTING COMPONENTS CAUTION Never use a circlip twice. When a circlip is removed, it must be replaced with a new one. When assembling a new circlip, be careful not to stretch its ends more than strictly necessary to place it on the shaft. After installing a circlip, make sure that it is completely and firmly inserted in its seat. Do not use compressed air to clean bearings. NOTE Bearings must turn freely with no sticking and/or noise.
General information Atlantic 500 POSITION OF SERIAL NUMBERS These numbers are required for vehicle registration. NOTE The alteration of the identification numbers is A an offence, punishable with criminal and administrative sanctions. In particular, the alteration of the frame number will result in the immediate invalidation of the warranty. VEHICLE IDENTIFICATION NUMBER (V.I.N.) (FRAME NUMBER) Every vehicle produced by aprilia receives a vehicle identification number (V. I. N.
General information Atlantic 500 ENGINE NUMBER The engine number is stamped near the lower rear shock absorber support. 1 Engine n° SAFETY WARNINGS FOR FUEL, LUBRICANTS COOLANT AND OTHER COMPONENTS FUEL WARNING The fuel used for the propulsion of combustion engines is extremely inflammable and can become explosive under certain conditions. Refueling and servicing operations should be carried out in well-ventilated areas with the engine switched off.
General information Atlantic 500 TRANSMISSION OIL WARNING Transmission oil can cause serious skin damage if handled on a daily basis over a long period of time. You are advised to wash your hands thoroughly after handling the oil. Do not dispose of the oil in drains, watercourses or the soil. Take the oil to (or have it collected by) the nearest used oil disposal agency or the supplier. You are advised to wear rubber gloves when carrying out maintenance work.
General information Atlantic 500 COOLANT WARNING Coolant is harmful if swallowed; it may cause irritation if it comes into contact with the eyes or skin. Rinse for a long time with water and call a doctor if coolant comes into contact with the skin or eyes. If swallowed, induce vomiting, rinse the mouth and throat with lots of water and call a doctor immediately. DO NOT DISPOSE OF THE FLUID IN DRAINS, WATER COURSES OR THE SOIL. KEEP OUT OF REACH OF CHILDREN.
General information Atlantic 500 CARBON MONOXIDE If a servicing operation has to be carried out with the engine running, make sure this is done in the open air or in a well-ventilated area. Never run the engine in enclosed spaces. If you have to work in an enclosed space, use an exhaust fume extraction system. WARNING Exhaust fumes contain carbon monoxide, a poisonous gas that can cause loss of consciousness and death.
General information Atlantic 500 PRECAUTIONS AND GENERAL INFORMATION Keep strictly to the following instructions when repairing, disassembling or reassembling the motorcycle. 1 WARNING Never use a naked flame for any operation whatsoever. Before starting any servicing or inspection job on the motorcycle, stop the engine, remove the key, wait until the engine and exhaust have cooled down and, if possible, raise up the motorcycle, using the correct equipment standing on a solid, level floor.
General information Atlantic 500 POSITION OF THE WARNING ADHESIVE LABELS A 17 12 5 11 B C 19 13 7 9 18 4 3 D E 10 1 8 16 1-10 15 2a 6 14 Release 00 2002-09 chap.
General information Atlantic 500 WARNING ADHESIVE LABELS CHART Ref. Description Ref. Description 1 1 2 10 NOT PROVIDED FOR 49 STATES. 11 FOR STATE OF CALIFORNIA ONLY. 12 2a 13 3 14 4 5 15 6 16 7 17 Muffler stamping. 8 18 9 19 chap.
General information Atlantic 500 CALIFORNIA EVAPORATIVE EMISSION SYSTEM 1-12 Release 00 2002-09 chap.
General information Atlantic 500 FOR STATE OF CALIFORNIA ONLY.
General information Atlantic 500 aprilia s.p.a. EMISSION CONTROL SYSTEM WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board and aprilia s.p.a. (hereinafter aprilia) are pleased to explain the emission control system warranty on your 1999 and later motorcycle. In California new motor vehicles must be designed, built and equipped to meet the State’s stringent anti-smog standards.
General information Atlantic 500 aprilia s.p.a. LIMITED WARRANTY ON EMISSION CONTROL SYSTEM aprilia s.p.a., Via G. Galilei, 1, 30033 Noale (VE) Italy (hereinafter aprilia) warrants that each new 1999 and later aprilia motorcycle, that includes as standard equipment a headlight, taillight and stop-light, and is street legal: A.
General information Atlantic 500 III. LIMITED LIABILITY A. The liability of aprilia under this Emission Control System Warranty is limited solely to the remectying of defects in material of workmanship by an authorized aprilia motorcycle dealer at its place of business during customary business hours. This warranty does not cover inconvenience or loss of use of the motorcycle or transportation of the motorcycle to or from the aprilia dealer.
General information Atlantic 500 TECHNICAL SPECIFICATIONS DIMENSIONS Max. length Max. width Max. height (al front fairing) Saddle height Wheelbase Minimum ground clearance Weight in operating condition 89.4 in (2270 mm) 28.3 in (720 mm) 57.0 in (1450 mm) 30.7 in (780 mm) 62.0 in (1575 mm) 5.9 in (150 mm) 440.
General information Atlantic 500 FUEL SUPPLY Type Fuel Electronic injection with electric fuel pump Unleaded gasoline (4 Stars ), with minimum octane rating of 95 (RON) and 85 (MON) FRAME Type Steering angle Trail High-resistance steel tubes 28°, 50’ 4.6 in (118 mm) SUSPENSIONS Front Stroke Hydraulically operated telescopic adjustable fork 3.93 in (100 mm) rear Two dual-effect hydraulic shock absorbers with pre-load with five settings 3.93 in (100 mm) Rear Wheel stroke BRAKES Front Disc - Ø 10.
General information Atlantic 500 ELECTRICAL SYSTEM Battery Fuses Alternator (with permanent magnet) 12 V - 14 Ah 30 - 20 - 15 - 3 A 14 V - 330 W BULBS Headlight / high beam Front parking light Rear / front direction indicators Rear parking / brake light Helmet compartement lighting License plate lamp Dashboard light Third brake lights 1 12 V - 55 W / 12 V - 35 W 12 V - 5 W rear 16 W - front 10 W 12 V - 5 / 21 W 12 V - 3 W 12 V - 5 W LED 12 V - 2.
General information Atlantic 500 TIGHTENING TORQUE CHART DESCRIPTION ftlb Nm FRAME ASSEMBLY Passenger footrest fastening screw 14.75 20 Steering lock plate screws 8.68 12 Locking ring nut 36.88 50 Key commutator blind fastening screw 7.23 10 Threaded bushing 2.21 3 Key commutator fastening screw 7.23 10 Windshield support fastening screw 7.23 10 Windshield support fastening nut 7.23 10 Damper to frame fastening screw 7.23 10 Nut 7.23 10 Damper fork side fastening screw 7.
General information Atlantic 500 DESCRIPTION ftlb Nm Wheel pin 36.88 50 Speedometer sensor screw 6.63 9 Hub screw 7.23 10 110.64 150 14.75 20 7.23 10 7.23 10 7.23 10 18.44 25 7.23 10 Coil fastening screw 1.47 2 Nut 1.47 2 Rotary switch screw 7.23 10 Rotary switch screw 7.23 10 Relay cable fastener 3.68 5 Reflector nut 1.10 1.5 Fuel pump flange self-locking M5 nut 2.21 3 2.21 3 2.21 3 5.90 8 5.
General information 1-22 Atlantic 500 Release 00 2002-09 chap.
Routine maintenance operations Atlantic 500 2 Routine maintenance operations chap.
Routine maintenance operations Atlantic 500 This section describes the routine maintenance procedures for the main components of the motorcycle. WARNING Before starting any maintenance or inspection job on the motorcycle, stop the engine and remove the key, and wait until the engine and exhaust system have cooled down. Place the motorcycle on a workstand, which is solidly attached to the floor. Raise the motorcycle up to the point where it may conveniently be worked on.
Routine maintenance operations Atlantic 500 SCHEDULED MAINTENANCE CHART OPERATIONS HANDLED BY THE aprilia dealer COMPONENTS Throttle cable (adjusting) Variator belt Steering bearings and steering Wheel bearings Engine oil filter Valve clearance Brake system Cooling system Brake light switches End of breaking-in 625 mi (1,000 km) Every 3,750 mi Every 7,500 mi (6,000 km) or 8 months (12,000 km) or 16 months 1 1 1 1 3 2 1 every 3,750 mi (6,000 km): 3 every 11,250 mi (18,000 km) 4 1 1 1 1 1 Brak
Routine maintenance operations Atlantic 500 LUBRICATION POINTS KEY TO LUBRICATION DIAGRAM Regular lubrication, using the correct lubricants, is an important factor in ensuring the long life and excellent performance of the motorcycle. 1) 2) 3) 4) 5) 6) 9) NOTE Before lubricating, completely clean the oxidation from all parts and remove all grease, dirt and dust. Any exposed parts subject to rusting, must be lubricated with engine oil or grease (see LUBRICANT CHART).
Routine maintenance operations Atlantic 500 BATTERY Carefully read (MAINTENANCE). After the first 625 mi (1,000 km) and every 3,750 mi (6,000 km) thereafter, check the electrolyte level and make sure the terminals are firmly tightened. WARNING 2 ZADI Danger of fire. Fuel and other flammable substances must be kept away from electrical components. PU SH Battery electrolyte is toxic, caustic and may burn in contact with the skin, since it contains sulfuric acid.
Routine maintenance operations Atlantic 500 REMOVAL BATTERY COVER 3 Carefully read (BATTERY). 4 NOTE Place the vehicle on a flat, hard surface. • • • • • • • Make sure that the ignition switch is set to “ ”. Lift the saddle, see (LOCKING/RELEASING THE SADDLE). Remove the rug lining the helmet compartment. Unscrew and remove the two screws (1). Slide the battery cover (2) out from below, being careful with the upper tabs (3). Disconnect the electrical connector (4) for the helmet compartment lighting.
Routine maintenance operations Atlantic 500 REMOVING THE BATTERY • • • • • Remove the battery cover, see alongside (REMOVING THE BATTERY COVER). Remove the battery bleed tube (7). Slide the battery (8) out of its seat, turning it slightly to the right as shown by the arrow. Disconnect the negative cable (-) and positive cable (+), in that order. Remove the battery (8) completely from its housing and place it on a flat surface, in un cool, dry place.
Routine maintenance operations Atlantic 500 CHECKING THE LEVEL OF BATTERY ELECTROLYTE To check the electrolyte level: • Remove the battery cover, see (REMOVING THE BATTERY COVER). • Make sure that the fluid level is between the two “MIN” and “MAX” notches stamped on the side of the battery. Otherwise: • Remove the plugs from the elements. CAUTION Use only distilled water to top up the electrolyte fluid. Do not exceed the reference “MAX”, since the level increases during recharging.
Routine maintenance operations Atlantic 500 BATTERY INSTALLATION • • Remove the battery cover, see (REMOVING THE BATTERY COVER). Place the battery in its housing. 1 CAUTION Always connect the battery bleed to the prevent escaping sulfuric acid fumes from corroding the electrical system, painted parts, rubber parts or gaskets. • • • • 2 Connect the positive (+) and negative (–) cables, in that order. Coat the terminals with neutral grease or Vaseline. Connect the battery bleed tube (1).
Routine maintenance operations Atlantic 500 • Use a strong blast of compressed air to prevent the residue removed from entering the engine. The spark plug must be replaced if it shows cracked insulation, corroded electrodes or excessive buildup. • Use a gauge to measure the spark plug gap. It should be 0.027-0.031 in (0.7-0.8 mm); adjust if necessary, carefully bending the earth electrode. • Make sure that the gasket is in good condition.
Routine maintenance operations Atlantic 500 AIR FILTER 1 Carefully read MAINTENANCE. You should clean and check the condition of the air filter every 3,750 mi (6,000 km), depending on use. If the vehicle is used on dusty or wet roads, clean or change the filter more frequently. 2 2 The filter element must be removed from the vehicle for cleaning. REMOVAL • Place the vehicle on the center stand. • Lift the saddle as described on (LOCKING/RELEASING THE SADDLE). • Remove the safety clip (1).
Routine maintenance operations Atlantic 500 ENGINE OIL Check the engine oil after the first 625 miles (1,000 km), that is, at the end of the run-in period. Check the oil again every 1,875 miles (3,000 km). Oil must be replaced every 3,750 miles (6,000 km), see ENGINE OIL CHANGE AND OIL FILTER. NOTE Use oil with 5/W 40 specifications, see (LUBRICANT CHART). CAUTION When topping up engine oil, we recommend that you never exceed the “MAX” level.
Routine maintenance operations Atlantic 500 CAUTION Do not fill beyond the “MAX” marking or below the “MIN” marking to avoid seriously damaging the engine. • Top up if necessary. 4 TOPPING UP • Add a small amount of oil through the filling hole (2) and wait about a minute for the oil to flow evenly within the half-case. • Check the oil level, and top up if necessary. • Top up with small amounts of oil until the prescribed level is reached. • When you have finished, tighten the cap/dipstick (1).
Routine maintenance operations • • Atlantic 500 Unscrew and extract the cap-dipstick (1). Unscrew and remove the engine oil cartridge filter (3). 1 2 WARNING Never use the vehicle with insufficient lubrication or with contaminated or inappropriate lubricants, as these accelerate wear on moving parts and may cause irreparable damage.
Routine maintenance operations • • • • Atlantic 500 Unscrew and extract the cap-dipstick (1). Use a clean cloth to clean the part in contact with the oil. Fully tighten the cap-dipstick (1) in the filling hole (2). Extract the cap-dipstick (1) again and read the level that oil reaches on the stick: 1 MAX MIN 2 MAX = maximum level MIN = minimum level • The level is correct if it approximately reaches the “MAX” level marked on the dipstick.
Routine maintenance operations Atlantic 500 CHANGING THE TRANSMISSION OIL Carefully read LUBRICANTS, MAINTENANCE and LUBRICANT CHART. NOTE Place the vehicle on a flat, hard surface. • Place the vehicle on the center stand. 1 WARNING The engine and exhaust system components become very hot, and remain hot for some time even after the engine has been shut off. Before handling these components, wear insulating gloves or wait until the engine and exhaust system have cooled down.
Routine maintenance operations Atlantic 500 WARNING The brakes are the parts that guarantee the most safety and therefore, they must always be kept in perfect working order. Always check the brakes before using the vehicle. A dirty disc will soil pads, which will lead to a reduction in braking efficiency. Dirty pads must be replaced, while a dirty disc must be cleaned using a high-quality degreaser. 2 Brake fluid must be replaced every two years.
Routine maintenance operations Atlantic 500 TOPPING UP BRAKE FLUID Carefully read DISC BRAKES. Unscrew the four screws (2) of the brake fluid tank (3). Remove the cover (4). NOTE In order not to spill brake fluid during topping up, keep the fluid in the tank parallel to the tank rim (in a horizontal position). Remove the gasket below the cover.
Routine maintenance operations Atlantic 500 BLEEDING THE BRAKING SYSTEM (FRONT ONLY) Carefully read DISC BRAKES. If air is present in the hydraulic system, it acts as a bearing and absorbs the majority of the pressure exercised by the brake pump, reducing the effectiveness of caliper action during braking. You can tell if there is air in the system from the “sponginess” of the brake control and reduced braking efficiency.
Routine maintenance operations Atlantic 500 BLEEDING THE INTEGRAL BRAKING SYSTEM Carefully read DISC BRAKES. If air is present in the hydraulic system, it acts as a bearing and absorbs the majority of the pressure exercised by the brake pump, reducing the effectiveness of caliper action during braking. You can tell if there is air in the system from the “sponginess” of the brake control and reduced braking efficiency.
Routine maintenance operations Atlantic 500 Unscrew and remove the three screws (7). Remove the rear brake caliper (8) from the plate (9) with relevant cable gland. Position the rear brake caliper (8) so that the bleeder nipple (10) is in the highest position. 8 9 7 2 7 Suck out the oil from the bleeder nipple (10) of the rear brake caliper (10) using the specific equipment (6), and unscrewing the bleeder nut (10) by half a turn. 10 Top up the oil in the brake fluid tank (2) approx. 2-3 times.
Routine maintenance operations Atlantic 500 CHECKING AND TOPPING UP COOLANT 2 Carefully read COOLANT and PRECAUTIONS AND GENERAL INFORMATION. CAUTION MAX Never use the vehicle if the coolant level is below minimum “MIN”. MIN Check the coolant level every 1,250 mi (2,000 km) and after long trips; replace every 16 months. DISPOSE OF COOLANT CORRECTLY. Place the vehicle on the center stand. Remove the front outer shield, see (REMOVING THE FRONT OUTER SHIELD).
Routine maintenance operations Atlantic 500 REPLACING THE COOLANT Carefully read COOLANT and PRECAUTIONS AND GENERAL INFORMATION. 1 CAUTION Never use the vehicle if the coolant level is below minimum “MIN”. Check the coolant level every 1,250 mi (2,000 km) and after long trips; replace every 16 months. 2 CAUTION Switch off the engine and wait until both the engine and the exhaust system are cool. DISPOSE OF FLUID CORRECTLY. Place the vehicle on the center stand.
Routine maintenance operations • • Atlantic 500 Start the engine and leave it running at minimum running speed. Place a container under the engine to collect the coolant that will spill out from the bleeder screw (5). 6 5 CAUTION The coolant is pressurized; loosen the bleeder screw (5) slowly and a little at a time in order to avoid splashing dangerous fluids.
Routine maintenance operations • • • Atlantic 500 Connect a transparent rubber pipe (2) between the bleeder and the expansion tank. Open the bleeder nut (3) by half a turn. Fill the expansion tank (4) with coolant until it reaches the max. mark (this can be seen in the window in the front compartment). 2 2 4 • • • • Start the engine. The circuit air bubbles out from the transparent rubber pipe (2).
Routine maintenance operations Atlantic 500 ADJUSTING THE PLAY OF THE BEARINGS Remove the leg shield, see (REMOVING THE LEG SHIELD). Loosen the counter nut (1). CAUTION Do not forcefully tighten or screw the register nut (2) in order not to damage the steering bearings. Tighten the register nut (2) until the bearing play has been recovered. Check the play by shaking the fork in the direction of travel and making sure that steering turns both freely and fluidly.
Routine maintenance operations Atlantic 500 CHECKING THE FRONT SUSPENSION Carefully read PRECAUTIONS AND GENERAL INFORMATION. Check the front suspension after the first 625 miles (1,000 km), and then every 3,750 miles (6,000 km) or every 8 months. Replace the front suspension oil every 7,500 miles (12,000 km), see (FRONT SUSPENSION). Check that the front fork shows no signs of oil leakage and that the outer surfaces of the rods are not scratched or grooved and if they are, replace all damaged parts.
Routine maintenance operations Atlantic 500 TABLE PRELOAD ADJUSTMENT FOR REAR SUSPENSION SPRING Adjuster ring-nut Rotation (arrow A) Rotation (arrow B) Function Increase spring preload Reduce spring preload Type of riding position The riding position of the vehicle is more rigid The riding position of the vehicle is softer Type of road recomm.
Routine maintenance operations Atlantic 500 If the tire is underinflated (pressure is too low), the sidewalls (1) are under greater stress and the tire itself may slip or detach from the rim with consequent loss of control. The tires may slip off the rims if the rider brakes suddenly, and the vehicle may skid on curves. 1 Check the surface state and wear, since tires in poor condition do not adhere properly to the road and adversely affect vehicle handling.
Routine maintenance operations Atlantic 500 MINIMUM TREAD DEPTH (2) front:............0.078 in [2 mm] ( rear:.............0.078 in [2 mm] ( 0.118 in) [3 mm] 0.118 in) [3 mm] 2 Do not exceed the maximum weight limit. Overload of the vehicle will compromise its stability and handling, and may damage the tires. MAX. LOAD 396.8 lbs (180 Kg) TIRE PRESSURE FRONT ONLY RIDER REAR 30.4 psi (2.1 bar) 33.3 psi (2.3 bar) FULL LOAD 31.9 psi (2.2 bar) 37.7 psi (2.
Engine Atlantic 500 3 Engine chap.
Engine Atlantic 500 ENGINE COMPONENTS THAT CAN BE REMOVED WITHOUT REMOVING THE ENGINE 5 The parts listed below can be removed and refitted without removing the engine from the frame.
Engine Atlantic 500 REMOVING THE ENGINE FROM THE FRAME 1 3 5 2 Read carefully (PRECAUTIONS AND GENERAL INFORMATION). 6 CAUTION Stop the engine and wait until the engine and exhaust system have cooled down. Disconnect the battery. 4 Bleed the cooling system completely (see REPLACING THE COOLANT). Remove the left- and right-hand inspection covers, see (REMOVING THE LEFT AND RIGHT INSPECTION COVERS).
Engine Atlantic 500 Disconnect the pump water inlet hose (8) by loosening the screw (9) of the hose clamp (10). 8 10 9 Disconnect the water outlet hose (11) from the cylinder by loosening the screw (12) of the hose clamp (13) on the coupling above the cylinder. 13 15 12 11 Disconnect the electric connection (14) of the coolant temperature sensor (15). 14 Loosen the two nuts (16) that fix the cable ducts to the throttle unit support.
Engine Atlantic 500 Slide out the rubber protection (21) and disconnect the connector of the engine oil pressure sensor (22). 21 22 3 Unscrew and remove the starter relay cable fastening nut (23) and slide out the cable (24). Unscrew and remove the two screws (25) that fix the starter motor to the casing and free the relevant grounding cables. Disconnect the connector (26) of the fuel injection positive cable.
Engine Atlantic 500 “A” Prepare suitable supports to place under the engine after it has been removed from the frame. “B” Unscrew and remove the fastening pin (27) of the left rear suspension (28). Retrieve the relevant nut and washer. 28 CAUTION Due to the heavy weight of the engine, work with caution and beware of hand injuries. “A” Accompany the engine until it is resting on the ground. 27 “B” Unscrew and remove the left pin (29) that fixes the engine to the frame and retrieve the washer.
Fuel system Atlantic 500 4 Fuel system chap.
Fuel system Atlantic 500 FUEL PUMP AND TANK EMS FUEL INJECTION SYSTEM This fuel injection system has integrated injection and ignition. Injection is indirect into the manifold, using an electronic fuel injector. Injection and ignition are phased to a 4-stroke cycle, using a phonic wheel dropped on the camshaft control and a reluctance variation sensor. Carburation and ignition are both controlled according to engine revs and gas valve opening.
Fuel system Atlantic 500 FUEL SUPPLY SYSTEM 5 3 10 4 7 6 4 8 1 9 2 FUEL SUPPLY SYSTEM KEY 1) Fuel pump 2) Fuel tank 3) Intake manifold 4) Fuel supply pipe (DELIVERY) 5) Fuel supply pipe (RETURN) 6) Excess gasoline bleeder pipe 7) Fuel injector 8) Fuel level float 9) Fuel pump filter 10) Filler cap chap.
Fuel system Atlantic 500 MAINTENANCE Check the condition of the tubing in the fuel system every 3,750 mi (6,000 km) or 8 months. Any pipes that show signs of drying, cracking or cuts must be replaced. Make sure that pipes are NOT twisted or choked. CHECKING THE FUEL SUPPLY SYSTEM Read carefully (PRECAUTIONS AND GENERAL INFORMATION) and (FUEL). CAUTION Fuel vapors are dangerous to health. Before proceeding, make sure that the place of work is sufficiently ventilated. Do not inhale fuel vapors.
Fuel system Atlantic 500 REMOVING/DISASSEMBLING THE FUEL PUMP CAUTION Work with caution when removing the fuel pump (5), taking care not to damage the fuel pre-filter (6). Read carefully (PRECAUTIONS AND GENERAL INFORMATION) and (FUEL). Remove the fuel pump (5) from the tank (7). REMOVING THE PUMP ASSEMBLY CAUTION Fuel vapors are dangerous to health. Before proceeding, make sure that the place of work is sufficiently ventilated. Do not inhale fuel vapors. Avoid fuel contact with skin.
Fuel system Atlantic 500 DISASSEMBLING AND CHECKING THE PUMP AND FUEL LEVEL PROBE To disassemble these parts, see the ENGINE WORKSHOP MANUALS n°1063 , n°1064 , n°1065 , n°1066 , n°1067 and n°1068 . THROTTLE UNIT 1) 2) 3) 4) 5) 6) Stepper motor Throttle position sensor Air temperature sensor Valve Valve opening cable support plate Valve opening/closing wiring control guide 6 2 5 4-6 1 4 Release 00 2002-09 3 chap.
Fuel system Atlantic 500 REMOVING THE THROTTLE UNIT Read carefully (PRECAUTIONS AND GENERAL INFORMATION) and (FUEL). Remove the air filter box, see (AIR FILTER). Disconnect the delivery and return fuel supply pipes (1) of the fuel injector. Unscrew and remove the screw (2) that fastens the fuel pipe guide fasteners. Disconnect the electric connection (3) of the fuel injector control. 1 4 2 3 Disconnect the electric connection (4) of the air temperature sensor.
Fuel system Atlantic 500 Unscrew and remove the three screws (10) that fasten the intake manifold (11) to the head. Remove the intake manifold (11) and throttle unit (12). 10 10 12 11 Unscrew and remove the three screws (13) that fasten the throttle unit (12) to the intake manifold (11). Remove the throttle unit (12) from the intake manifold (11). Unscrew and remove the screw (14) that fastens the fuel injector (15) to the intake manifold. Remove the fuel injector (15) from the intake manifold (11).
Cooling system Atlantic 500 5 Cooling system chap.
Cooling system Atlantic 500 SYSTEM DESCRIPTION The cooling system is comprised of a centrifugal pump that is coaxial to the countershaft and for this reason, it makes the same number of revolutions as the engine shaft. The pump has two intake pipes and one outlet pipe. The outlet feeds the cylinder and as a result, the head; one intake comes from the head and is controlled at the pump intake by the thermostat cap.
Cooling system Atlantic 500 REMOVING THE RADIATOR Read carefully (COOLANT) and (PRECAUTIONS AND GENERAL INFORMATION). 1 Empty the coolant completely, see (REPLACING COOLANT), in the ENGINE WORKSHOP MANUALS n°1063 , n°1064 , n°1065 , n°1066 , n°1067 and n°1068 . 1 Remove the leg shield, see (REMOVING THE LEG SHIELD). Remove the front splash guard, see (REMOVING THE SPLASH GUARD). Remove the heat-reflecting material. Disconnect the three hoses (1) on the radiator.
Cooling system Atlantic 500 REMOVING THE EXPANSION TANK Read carefully (COOLANT) and (PRECAUTIONS AND GENERAL INFORMATION). Position the motorcycle on the center stand. Remove the front outer shield, see (REMOVING THE FRONT OUTER SHIELD). Remove the leg shield, see (REMOVING THE LEG SHIELD). Remove the dashboard, see (REMOVING THE DASH BOARD). CAUTION DO NOT DISPOSE OF COOLANT IN THE ENVIRONMENT. When the hose (1) is disconnected, the coolant contained in the expansion tank (2) will run out.
Cooling system Atlantic 500 THERMOSTAT VALVE For information on the thermostat valve, see ENGINE WORKSHOP MANUAL n°1063 , n°1064 , and n°1068 . n°1065 , n°1066 , n°1067 COOLANT PUMP 5 For information on the coolant pump, see ENGINE WORKSHOP MANUAL n°1063 , n°1064 , n°1065 , n°1066 , n°1067 and n°1068 . COOLANT THERMISTOR For more information about the coolant thermistor, see ENGINE WORKSHOP MANUALS n°1063 , n°1064 , n°1065 , n°1066 , n°1067 and n°1068 . chap.
Cooling system 5-6 Atlantic 500 Release 00 2002-09 chap.
Electrical system Atlantic 500 6 Electrical system chap.
Electrical system Atlantic 500 CHECKING THE RECHARGE SYSTEM Refer to the following key when consulting this section. CABLE COLOURS Ar orange Az light blue B blue Bi white G yellow Gr grey M brown N black R red V green Vi violet Ro pink CHECKING THE RECHARGE VOLTAGE • Check the electrolyte level (see CHECKING THE ELECTROLYTE LEVEL). • Check the battery voltage (see RECHARGING THE BATTERY). • Start the engine and take it to 5,000 rpm (throttle control turned approximately 1/4 of its range).
Electrical system Atlantic 500 CHECKING THE ALTERNATOR CONTINUITY With the engine off: • Remove the right side panel, see (REMOVING THE SIDE PANELS). • Disconnect the regulator wires connector (1). • Using a portable tester, test the continuity between the yellow wires (G) of the stator. • Also, check the isolation of the stator support. 1 1 Standard resistance: 0.
Electrical system Atlantic 500 IGNITION SYSTEM FUEL INJECTION SUPPLY WIRING DIAGRAM 37 R/Gr R/N 35 1 V/N R/Bi R/Gr R/Gr Ar/N Ar/V 24 B 15A V/N C 15A E 3A V/R A 15A V/R D 15A F STAND SPIA SWITCH CAVALLETTO R/Bi 1 2 3 4 R/B 5 6 7 8 9 10 11 12 13 14 15 16 Ar/N 17 18 19 20 21 22 23 24 25 Gr/N 26 V/R 52 E.C.U. CONTROL UNIT CENTRALINA E.C.U.
Electrical system Atlantic 500 CHECKING THE STAND SWITCH The rotation of the side stand (1) must be free of any impediments. Make the following checks: • • The springs (2) must not be damaged, worn, rusty or weakened. The stand must rotate freely; grease the joint if necessary, see (LUBRICANT CHART). A safety switch (3) is fitted to the side stand (1) to prevent or interrupt engine operation when the side stand (1) is lowered.
Electrical system Atlantic 500 CHECKING THE FUEL INJECTION RELAY To check the working state of the relay switch, proceed as follows: • • • Remove the rider’s saddle, see (REMOVING THE RIDER’S SADDLE). Energize (12V) the two male terminals (85-86). Use a tester (as an ohmmeter) to check the continuity between the other two terminals (8730).
Electrical system Atlantic 500 IGNITION/FUEL INJECTION SYSTEM CONNECTIONS TO THE ELECTRONIC CONTROL UNIT 43 ! x1000r/min mp/h Km/h EFI ABS SET TRIP 36 M/Bi 3 4 5 6 7 Az/R Ar R/B Vi B 9 10 11 12 13 14 15 16 M R M/G B/N Gr/R Az Az/V Ro/G 6 R M 1 B 54 3 POMPA FUEL BENZINA PUMP 4 2 Gr Ar Ar/R Bi/N Gr Ro/N Gr M/Bi M/G R/M R/M Gr/R 1 Ar/Bi R/M Az Ro G Vi 1 Gr/N R/B R/M 18 Ro/N Vi/N 19 Ar/Bi 20 G 21 Gr 22 23 N 24 Ro 25 Gr/N 26 N 52 E.C.U. CONTROL UNIT CENTRALINA E.C.U.
Electrical system Atlantic 500 1 2 3 4 6 5 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 CAUTION Since there are diodes, condensers and other electrical components inside the C.D.I. control unit, the measuring method indicated is approximate. We recommend carrying out another check by replacing the control unit with another perfectly operating unit, or by carrying out the checks listed in the chapter (CHECKING THE ELECTRICAL SYSTEM FROM THE C.D.I.
Electrical system Atlantic 500 CONNECTIONS TO THE E.C.U. CONTROL UNIT COMPONENT TERMINAL RATED VALUE CABLE COLOURS RPM Sensor 7 - 12 680 Ω B - B/N Stepper Motor 14 - 24 52 Ω Az - Ro Stepper Motor 6 - 21 52 Ω Vi - G Accelerator Sensor 1 - 22 5 kΩ M/Bi - Gr Accelerator Sensor 1 - 11 1 - 6 kΩ M/Bi - M/G Fuel Inj. Air Terminal 18 - 22 see tab. Ro/N - Gr Fuel Inj. H2O Terminal 4 - 22 see tab. Ar - Gr Drop Sensor 16 -22 62 kΩ * Ro/G - Gr Coil 20 0.
Electrical system Atlantic 500 CHECKING THE HT COIL • Remove the left side inspection cover (see REMOVING THE LEFT INSPECTION COVER). • Disconnect the terminal (1). • Unscrew and remove the two screws (2). • Disconnect the spark plug cap (3). • Remove the coil (4). 4 3 2 1 • • Use a pocket tester (scale 200 Ω) to measure the resistance (coil side) between the terminals shown in the figure (A and B). If the resistance is incorrect, replace the coil. B Standard value: 0.6 Ω ± 0.
Electrical system Atlantic 500 CHECKING THE DROP SENSOR 2 With the engine off: • 1 Remove the front cover, see (REMOVING THE FRONT COVER). Check that the sensor (1) is correctly fitted (with the arrow printed on the rubber element facing upwards). • • 3 Partially remove the fuse block (2). Disconnect the two-way connector (3) (white/ gray) and carry out the relevant measurements (on the sensor-side terminals).
Electrical system Atlantic 500 CHECKING THE RPM SENSOR With the engine off: • Disconnect the three-way connector (1) and carry out the relevant measurements. • Use a tester (scale x 100 Ω) to measure the resistance between the sensor terminals, respecting the relevant polarity (see figure). 1 Standard value: 680 Ω ± 10% • If the resistance is infinite or different from the prescribed value, the sensor must be replaced. + 6-12 Release 00 2002-09 chap.
Electrical system Atlantic 500 CHECKING THE THROTTLE POTENTIOMETER (ACCELERATOR SENSOR) With the engine off: • Disconnect the three-way sensor (black) (1). 1 CAUTION On reassembly, make sure that the electric connector (1) is correctly coupled. • • Set the ignition switch to “ ”. Use a tester (scale kΩ) to measure the resistance between the potentiometer terminals.
Electrical system Atlantic 500 CHECKING THE FUEL INJECTOR With the engine off: • Disconnect the two-way connector (black) (1) and carry out the relevant measurements (on the injector-side terminals). • Use a tester (scale x 100 Ω) to measure the resistance between the fuel injector-side terminals. 1 2 Standard value: 14.5 ± 10% Ω at 45°F (25°C) If resistance is infinite (∞) or lower than the prescribed value, the injector (2) must be replaced.
Electrical system Atlantic 500 CHECKING THE FUEL PUMP • • (direct current) Energize terminals 1 and 4 of the pump connector with 12 V DC. Check that the pump operates, emitting its characteristic buzzing sound, and check that the supply pressure on the pressure gauge reaches at least 150 KPa (1.5 bars). CAUTION Respect pump polarity. CHECKING THE CONDITION OF THE AIR THERMISTOR 6 2 CAUTION On reassembly, make sure that the electrical connector (1) is correctly coupled.
Electrical system Atlantic 500 STARTER AND STOP LIGHT SYSTEM 37 34 35 R/Gr R/N V/G G/R V/G R/N Gr/N V/G 33 1 R/N B/G B V/G 30 85 86 87 V/N R/Bi 55 R/Gr Gr/N R/N B/G G/R B/G Gr/N 1 56 1 V/G B V/G B V/G B V/G B V/G B 24 B 15A V/N C 15A E 3A A 15A V/R D 15A F V/R Ar/V V/G B V/R R/Bi R/Gr V/G B G/R B 1 R R N N R R 22 R/Bi B/Bi B M/N N V M 85 86 87 30 M/N R/N Gr/N Ar/V R R 30A V/R R 20A R/Bi 1 M 21 9 19 11 20 Key 9) Main injection relay 11) Side stand switch 19) B
Electrical system Atlantic 500 CHECKING THE STARTER RELAY • Disconnect the two-way connector (1) (white). CAUTION On reassembly, make sure that the electrical connector (1) is correctly coupled. • • • • • 1 Slide the relay (2) from its hooks. Slide out the two rubber protections (3-4). Disconnect the cables from the relevant relay (2) terminals. Energize (12 V) the two terminals inside the connector (1) from the relay side.
Electrical system 7) ENGINE STOP SWITCH ( Wires Pos R/N Atlantic 500 - ) R/Gr 8) STARTER BUTTON ( ) Wires Pos V/G G/R 9) IGNITION SWITCH G/Gr G V/N R/Bi ZADI Wires Pos 9 PUSH 10) FRONT STOP LIGHT SWITCH Wires Pos Gr/N V/G ON 11) REAR STOP LIGHT SWITCH Wires Pos V/G R/N ON 10 11 12) SIDE STAND SWITCH Wires N( ) Pos V M OPEN CLOSED 12 6-18 Release 00 2002-09 chap.
Electrical system Atlantic 500 ELECTRIC COOLING FAN WIRING DIAGRAM 35 38 G/N R/Bi Vi/N V V/N R/Bi 30 87 85 86 1 24 V B 15A V/N C 15A E 3A A 15A D 15A F 6 R/Bi Vi/N B G/N 22 Gr Ar R 30A R/Bi 1 N E.C.U. CONTROLE.C.U. UNIT CENTRALINA 52 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 16 R N B G/N 1 19 15 Key 15) Water thermistor 16) Fan 19) Battery 24) Secondary fuses 35) Key commutator 38) Fan relay 52) E.C.U.
Electrical system Atlantic 500 CHECKING THE WATER THERMISTOR See (CHECKING THE CONDITION OF THE COOLANT THERMISTOR) on page 6-14. CHECKING THE FANS RELAY To check the working state of the relay, proceed as follows: • • • Remove the rider’s saddle, see (REMOVING THE RIDER’S SADDLE). Energize (12 V) the two male terminals (85-86). Use a tester (as an ohmmeter) to check the continuity between the other two terminals (87-30).
Electrical system Atlantic 500 COOLANT TEMPERATURE AND FUEL LEVEL GAUGE WIRING DIAGRAM 43 ! x1000r/min mp/h Km/h EFI ABS SET TRIP 6 B V B 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Ar/R B B 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 Bi/N W 35 V/N R/Bi 1 24 B 15A V/N C 15A E 3A A 15A D 15A F R/Bi V Ar/N G/V Ar/R Bi/N R 20A R/Bi 1 22 R N 1 8 19 15 Key 8) Fuel level probe 15) Water thermistor 19) Battery 22) Main fuses 24) Secondary fuses 35) Key commutator 43) Dashbo
Electrical system Atlantic 500 WATER TEMPERATURE CHECKING THE DASHBOARD • • Disconnect the connector of the water thermistor and connect (from the connector side) an electrical resistor between the orange/red and black/white cables. Turn the key to ON and check the signal on the dashboard.
Electrical system Atlantic 500 LIGHTING AND SOUND SIGNAL SYSTEM WIRING DIAGRAM 39 SCROLL 37 PASSING STOP G V/N G/N 40 B Gr G/N N Bi V/N 35 48 G/Gr G V/N R/Bi G/Gr V G/N B Gr G/N N Bi V V Gr 1 N B N B Bi G B Bi 49 N B Bi G B Bi G B G B G B G G G B B G B G B B R/Bi 50 54 58 31 31 58 54 31 31 1 26 G/Gr B 6 G B B Ar/N 27 1 24 B G B 15A V/N C 15A E 3A V/R A 15A V/R D 15A R/Bi F V/R R/Bi 25 V/R V N 22 R R R R 30A V/R R 20A R/Bi 1 19 Key 19) Battery 22)
Electrical system Atlantic 500 DIRECTION INDICATORS AND DISPLAY DATA WIRING DIAGRAM 43 ! 39 SCROLL x1000r/min EFI mp/h Km/h PASSING STOP ABS SET 46 B/Bi M B/Bi Bi/G 1 R B/N Az 15 16 R/Bi B/N Az/Bi TRIP 12 R Az B/N R/Bi Az/Bi Bi/G 5 6 7 8 B/Bi W 1 R R 29 Az 30 R R R R Az Az 47 Az Key 29) Right rear direction indicator 30) Left rear direction indicator 39) Left dimmer 43) Dashboard 46) Front right direction indicator 47) Front left direction indicator HANDLEBAR LEFT SIDE
Electrical system Atlantic 500 MULTIFUNCTION LCD When the ignition key (1) is turned to position “ ”, on the multifunction LCD all segments are activated (this performs a functional test of the components) and the last function set after the vehicle was stopped will be displayed. 9 8 10 11 AVG VBATT Km/h ml/G Vmax mph 4 After the first 1,000 Km and every 6,000 Km thereafter, the message SERVICE appears on the display.
Electrical system Atlantic 500 RESETTING THE AVERAGE SPEED, MAXIMUM SPEED, FUEL CONSUMPTION LEVELS AND STOPWATCH VALUES NOTE the corresponding information may be reset only if the right digital display shows the odometer. ABS Hold down the key (1) (TRIP/RESET) for more than three seconds. /RESET NOTE The function displayed will be reset. 1 START/STOP AND RESETTING THE STOPWATCH NOTE the corresponding information may be reset only if the right digital display shows the odometer.
Electrical system Atlantic 500 VISUAL SIGNALS AND SPEEDOMETER WIRING DIAGRAM 43 ! x1000r/min mp/h Km/h EFI ABS 44 W SET TRIP Ro M 1 Gr/B Gr/Bi B/Ar Ro M 1 Gr/B Gr/Bi Vi 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 B/Ar Vi B/Ar Gr/Bi V 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 6 42 B 45 Key 42) 43) 44) 45) Dashboard air temperature thermistor Dashboard Speed sensor Oil pressure sensor chap.
Electrical system Atlantic 500 CHECKING THE DASHBOARD • If the dashboard is working correctly, when the ignition switch is in the “ ” position, the red LED “ ” of the oil pressure should light up. 1 2 CHECKING THE SENSOR • • • When the ignition switch is in the “ ” position, the red LED “ ” of the engine oil pressure should light up. If the red LED “ ” does not light up, check the working state of the sensor.
Electrical system Atlantic 500 SPEEDOMETER • • • Check the correct coupling of the speed sensor connector (1). Check the correct coupling of the dashboard connectors (2). Check the distance between the speed sensor (3) and the screws (4) that fasten the front brake disc. 1 Distance between sensor (3) and screws (4): 1.5 ± 1 mm. • Make sure that all screws (4) are fitted.
Electrical system Atlantic 500 AIR TEMPERATURE SENSOR To check the working state of the air temperature sensor, proceed as follows: • • Disconnect the two-way connector (1). Check the sensor in an environment with a controlled temperature of 68 °F (20 °C). • Use an ohmmeter (scale 0-20 kΩ) to measure electrical resistance between the terminals of the connector (1). 1 1 Ω - 12.700 kΩ Ω Correct value: 12.
Electrical system Atlantic 500 SWITCHES 3 2 5 Using a portable tester, check the continuity of the switches, and refer to the specific table for each switch. Replace the switch if it is faulty.
Electrical system Atlantic 500 CHANGING BULBS WARNING Before changing a bulb, turn the ignition switch to the “ ” position and wait a few minutes so that the bulb cools down. Change the bulb wearing clean gloves or using a clean and dry cloth. Do not leave fingerprints on the bulb, since these may cause its overheating and consequent breakage. If you touch the bulb with your bare fingers, remove any fingerprints with alcohol in order to avoid any damage. TAKE CARE TO AVOID DAMAGING THE ELECTRIC CABLES.
Electrical system Atlantic 500 BATTERY For safety standards and general information about the battery, see (BATTERY). For all other information, see (CHECKING THE ELECTROLYTE LEVEL), (RECHARGING THE BATTERY) and (LEAVING THE BATTERY IDLE FOR LONG PERIODS). ACTIVATING THE BATTERY 6 Carefully read (BATTERY). • • • • Remove the battery cover, see (REMOVING THE BATTERY COVER). Remove the battery, see (REMOVING THE BATTERY). Check the electrolyte level in the battery, see (CHECKING THE ELECTROLYTE LEVEL).
Electrical system Atlantic 500 HIGH BEAM BULBS • Turn the bulb socket/bulb (8) counter-clockwise and remove it from the reflector seat. 9 10 CAUTION To remove the bulb socket/bulb from the connection, be especially careful not to damage the two tabs (9). • • • Remove the bulb (10). Correctly install a new bulb of the same type. For reassembly, proceed in reverse order. 8 PARKING LIGHT BULBS 12 CAUTION 11 To remove the bulb socket do not pull the electrical cables.
Electrical system Atlantic 500 CAUTION During the following operations do not pull or force the electrical cables. • 4 Pull out the set of taillights (4), first removing the upper part and then distancing it from the housing. 5 3 CAUTION Work very carefully. Do not damage the tabs and/or slots into which they are fitted. • OWorking with the set of taillights in hand, turn it counter-clockwise and extract the bulb socket (5) with the bulb (6) of the reflector (4). • Remove the bulb from its seat.
Electrical system Atlantic 500 CHANGING THE LICENSE PLATE LAMP BULB 1 Carefully read (BULBS). To replace: CAUTION Do not pull on the wires to remove the bulb socket. • • 2 Grasp the socket (1), pull it and remove it from its seat. Remove the bulb (2) and replace it with another of the same type. CHANGING THE HELMET COMPARTMENT LIGHT BULB Carefully read (BULBS). 2 To replace: • Lift the saddle, see (LOCKING/RELEASING THE SADDLE).
Electrical system • • • Atlantic 500 Loosen and remove the two screws (3) that fasten the protective shield (4) of the third stop light. Slide the all-glass bulb (5) from its socket. Correctly fit a bulb of the same type. 3 NOTE On reassembly, place the protective shield 5 correctly in its seat. 6 CAUTION Tighten the screw (3) slightly and with care to avoid damaging the protective shield.
Electrical system Atlantic 500 HORIZONTAL ADJUSTMENT HEADLIGHT BEAM • Remove the front hood, see (REMOVING THE FRONT HOOD). To adjust the headlight beam: • Adjust the knob (as shown in the figure) from the front of the vehicle. • Turn CLOCKWISE to move the beam to the RIGHT (facing the direction in which the vehicle travels). • Turn COUNTER-CLOCKWISE to move the beam to the LEFT (facing the direction in which the vehicle travels). CHANGING FUSES Carefully read (MAINTENANCE).
Electrical system Atlantic 500 SECONDARY FUSE LAYOUT (FRONT HOOD) – 15A Fuse (2) From voltage regulator to: injection, rear brake/starting lights logic (Seat A on the wiring diagram). – 15A Fuse (3) From ignition switch to: engine kill, rear brake lights logic (Seat B on the wiring diagram). – 15A Fuse (4) From ignition switch to: lights, horn, dashboard, fan relay, radio power supply (Seat C on the wiring diagram). – 15A Fuse (5) From the main fuse to the power socket in the storage compartment.
Electrical system Atlantic 500 ELECTRIC COMPONENTRY POSITIONS 43 33 39 25 3 13 47 56 24 31 28 30 51 53 49 27 50 55 23 40 16 Key 3) Stepper motor 4) Coil 5) Spark plug 6) Fuel injector 11) Side stand switch 13) Throttle sensor 14) Engine air thermistor 15) Engine/dashboard H2O thermistor 16) Fan 23) Current socket 24) Secondary fuses 25) Storage compartment light 27) License plate lamp 6-40 6 Release 00 11 4 5 14 28) Radio power supply 30) Left rear direction indicator 31) Park
Electrical system Atlantic 500 ELECTRIC COMPONENTRY POSITIONS 20 22 2 35 34 37 19 38 36 32 9 31 29 10 17 48 26 42 45 6 46 21 18 Key 2) rpm sensor 7) Fuel pump 8) Fuel level probe 9) Main injection relay (with diode) 10) Secondary injection relay 17) Voltage regulator 18) Flywheel 19) Battery 20) Starter relay 21) Starter motor 22) Main fuses 26) Storage compartment light switch 29) Right rear direction indicator chap.
51 50 47 G B B Az G B R N B Bi G Az SECONDARY FUSES: B Bi B Bi N B R B 1 52 R N B Bi G Az A - FUEL INJECTION, START. B - ENGINE KILL, STOP LIGHTS. C - LIGHTS, HORN, DASHBOARD, FAN RELAY. D - POWER SOCKET. E - E.C.U. PERMANENT POWER SUPPLY. F - FREE.
Electrical system Wiring diagram legend 1) Multiple connectors 2) rpm sensor 3) Stepper motor 4) Coil 5) Spark plug 6) Fuel injector 7) Fuel pump 8) Fuel level probe 9) Main injection relay (with diode) 10) Secondary injection relay 11) Side stand switch 12) Lambda probe (not available) 13) Throttle sensor 14) Engine air thermistor 15) Engine/dashboard H2O thermistor 16) Fan 17) Voltage regulator 18) Flywheel 19) Battery 20) Starter relay 21) Starter motor 22) Main fuses 23) Current socket 24) Secondary fu
Electrical system 6-44 Atlantic 500 Release 00 2002-09 chap.
Cycle parts Atlantic 500 7 Cycle parts chap.
Cycle parts Atlantic 500 BODYWORK REMOVING THE PASSENGER FOOTBOARDS 1 1 Place the motorcycle on the center stand. CAUTION Proceed with care. Unscrew and remove the 3 screws (1). Remove the passenger footboard (2). 2 REMOVING THE BOTTOM GUARD 3 Place the motorcycle on the center stand. CAUTION Proceed with care. Do not damage the tabs and/or corresponding tab slots. Handle painted parts carefully, without scraping or damaging them.
Cycle parts Atlantic 500 REMOVING THE SADDLE 4 Place the motorcycle on the center stand. Lift the saddle (4), see (UNLOCKING/LOCKING THE SADDLE). CAUTION Proceed with care. Use suitable pincers to slide out the clip (5). 6 5 7 CAUTION Keep the saddle raised to prevent it from falling freely. Slide out the pin (6). Unscrew and remove the four nuts (7). Remove the saddle (4). 7 REMOVING THE CENTRAL TUNNEL Place the motorcycle on the center stand.
Cycle parts Atlantic 500 REMOVING THE RIGHT AND LEFT INSPECTION COVERS 1 2 Place the motorcycle on the center stand. Remove the right or left mat (1) by lifting it with your hands. Unscrew and remove the screw (2). CAUTION Proceed with care. Do not damage the tabs (3) and/or the slots in which they fit. Handle the plastic and painted components with care to avoid scraping or damaging them. Use a screwdriver to force up the bottom of the inspection cover (4), until it leaves its seat.
Cycle parts Atlantic 500 Using a flathead screwdriver (3), prize the speaker cover (4) away from its seat, as shown in the figure. Remove the speaker cover (4). 3 4 Unscrew and remove the two screws (5). 5 7 CAUTION Proceed with care. Do not damage the tabs and/or corresponding tab slots. Handle painted parts carefully, without scraping or damaging them. 3 Using a flathead screwdriver (3) along the perimeter of the leg shield, prize it away from its slots.
Cycle parts Atlantic 500 Pull the tabs (7) towards the cable (9), in order to lift and free the cable end (8). Pull the cable (9) in the direction shown by the arrow in order to free the leg shield from the storage compartment closure. Remove the leg shield (10). 7 8 9 10 STORAGE COMPARTMENT 1 Thanks to the storage compartment, you do not need to carry inconvenient items with you whenever you park your vehicle. Insert the key (1) in the ignition switch (2). Press and turn the key clockwise.
Cycle parts Atlantic 500 REMOVING THE PASSENGER HANDLES 8 Place the motorcycle on the center stand. CAUTION 9 Proceed with care. Do not damage the tabs and/or corresponding tab slots. Handle painted parts carefully, without scraping or damaging them. Lift the saddle, see (UNLOCKING/LOCKING THE SADDLE). Using a small flathead screwdriver, prize off the two rubber caps (8). Unscrew and remove the two screws (9). Remove the passenger handle (10) by turning it inwards towards the vehicle.
Cycle parts Atlantic 500 REMOVING THE CHROME-PLATED SIDE PANEL STRIP Remove the complete side panel, see (REMOVING THE WHOLE SIDE PANELS). 1 CAUTION Proceed with care. Do not damage the tabs and/or corresponding tab slots. Handle painted parts carefully, without scraping or damaging them. Unscrew and remove the screw (1), located inside the whole side panel. Remove the chrome-plated strip by gently bending it in the center.
Cycle parts Atlantic 500 1 REMOVING THE FOOTREST Place the motorcycle on the center stand. Remove the rubber footrest cover (1) by lifting it off manually. Remove the sparkplug access cover (A). A CAUTION Proceed with care. Do not damage the tabs and/or corresponding tab slots. Handle painted parts carefully, without scraping or damaging them. Unscrew and remove the 7 screws (2). Remove the foot rests (3). 2 3 2 7 REMOVING THE SPLASH GUARD Place the motorcycle on the center stand.
Cycle parts Atlantic 500 REMOVING THE FRONT SHIELD 3 Remove the splash guard, see (REMOVING THE SPLASH GUARD). Remove the leg shield, see (REMOVING THE LEG SHIELD). CAUTION 1 Proceed with care. Do not damage the tabs and/or corresponding tab slots. Handle painted parts carefully, without scraping or damaging them. 1 2 Unscrew and remove the 3 screws (1) (three on the right and three on the left). Free the front shield (2) from its supports by prizing out its tabs (3) with a flathead screwdriver.
Cycle parts Atlantic 500 Unscrew and remove the 7 screws (3). Disconnect the electric connection (4). Remove the support arch (5). 6 3 4 5 3 3 3 Lift and remove the plastic part (6) of the backrest. 7 REMOVING THE REAR MUDGUARD 2 Place the motorcycle on the center stand. CAUTION Proceed with care. Do not damage the tabs and/or corresponding tab slots. Handle painted parts carefully, without scraping or damaging them. 1 Unscrew and remove the two screws (1). Remove the license plate light cover.
Cycle parts Atlantic 500 Still holding the rear mudguard, disconnect the license plate light bulb (5), slide out the battery bleeder pipe (6) from its guide clip (7). Remove the rear mudguard (4). 5 4 6 7 REMOVING THE REAR PART OF THE FAIRING 1 Remove the plastic parts of the backrest, see (REMOVING THE PLASTIC PARTS OF THE BACKREST). Remove the rear mudguard, see (REMOVING THE REAR MUDGUARD). Remove the rear light assembly, see (REMOVING THE COMPLETE SIDE PANELS). Unscrew and remove the 3 screws (1).
Cycle parts Atlantic 500 REMOVING THE FOOTREST SUPPORT AND BOTTOM SPLASH GUARD Remove the leg shield, see (REMOVING THE LEG SHIELD). Remove the central tunnel, see (REMOVING THE CENTRAL TUNNEL). Unscrew and remove the two screws (1). Remove the chrome-plated protection pipe (2). 2 1 Unscrew and remove the 5 screws (3). Remove the footrest support (4). 4 3 7 Support the bottom splash guard (5). Disconnect the bleeder pipe (6) from the coolant tank. Remove the bottom splash guard (5). 6 5 chap.
Cycle parts Atlantic 500 REMOVING THE FRONT HOOD 1 1 Place the motorcycle on the center stand. Unscrew and remove the two screws (1). CAUTION Proceed with care. Do not damage the tabs and/or corresponding tab slots. Handle painted parts carefully, without scraping or damaging them. ABS Unscrew and remove the two screws (2). CAUTION When disassembling, be careful to keep the clips installed on the tabs from falling out.
Cycle parts Atlantic 500 Unscrew and remove the two screws (4) on the left and right of the vehicle. Remove the top handlebar cover (5). 4 4 REMOVING THE BOTTOM HANDLEBAR COVER 2 2 Remove the top handlebar cover, see (REMOVING THE TOP HANDLEBAR COVER). Unscrew and remove the 3 screws (1). Separate the plastic parts (2) by pulling them outwards. 1 1 7 REMOVING THE COMPLETE DASHBOARD Place the motorcycle on the center stand. CAUTION 2 Proceed with care.
Cycle parts Atlantic 500 Remove the front hood, see (REMOVING THE FRONT HOOD). Remove the windshield, see (REMOVING THE WINDSHIELD). Unscrew and remove the screw (4). 4 Lift away the complete dashboard (5), disconnect the electric connections (6) directly from the dashboard. Remove the complete dashboard (5). 5 6 REMOVING THE FRONT FAIRING 2 Carefully read (MAINTENANCE). Place the motorcycle on the center stand. Removing the front hood, see (REMOVING THE FRONT HOOD).
Cycle parts Atlantic 500 REMOVING THE COMPLETE LIGHT UNIT 1 Remove the front hood, see (REMOVING THE FRONT HOOD). Remove the windshield, see (REMOVING THE WINDSHIELD). Remove the front shield, see (REMOVING THE FRONT SHIELD). Remove the complete dashboard, see (REMOVING THE COMPLETE DASHBOARD). Unscrew and remove the screw (1). 6 4 Unscrew and remove the two screws (2) being sure to keep the relevant self-locking nut. Unscrew and remove the screw (3). Unscrew the coolant filler cap (4).
Cycle parts Atlantic 500 REMOVING THE HELMET COMPARTMENT Remove the saddle, see (REMOVING THE SADDLE). Remove the central tunnel, see (REMOVING THE CENTRAL TUNNEL). Remove the left and right side panels (see REMOVING THE WHOLE SIDE PANELS). Unscrew and remove the two screws (1), making sure to keep the relevant washers. (Repeat this operation on the right side also) 1 Unscrew and remove the two screws (2) that fasten the saddle lock (3) to the helmet compartment and free the lock from the compartment.
Cycle parts Atlantic 500 Slide the starter relay (6) out from its seat in the battery compartment. Use a hand to support the relay and slide off the rubber protection cap (7). Unscrew and remove the nut (8). 7 8 6 Slide the cables from the helmet compartment out to the rear. Slide out the starter relay cable (9). Slide out the battery cable (10). Slide out the ground cable (11). Slide out the fuse wire (12). 10 12 11 9 7 Disconnect the battery bleeder pipe (13) from its clip (14).
Cycle parts Atlantic 500 Unscrew and remove the two screws (18). 18 Unscrew and remove the four screws (19) of the carburetor cover (20). Remove the carburetor cover (20). 19 20 Use the screw (21) to loosen the clamp (22) and slide out the fuel suction hose (23) by pulling it outwards. 23 21 22 Unscrew and remove the six screws (24) of the filter case (25). 24 25 24 7-20 Release 00 2002-09 chap.
Cycle parts Atlantic 500 NOTE Be sure to have prepared a new clamp to replace the old one. 26 Remove the hose clamp (26) and slide out the pipe (27). Remove the engine cover (25) by lifting it upwards. Disconnect the electric connection (28) of the helmet compartment light switch. Remove the helmet compartment (29) by lifting the front section upwards and moving the whole block forwards. 27 29 28 7 chap.
Cycle parts Atlantic 500 FRONT WHEEL 6 2 4 5 11 7 3 10 8 9 12 1 KEY 1) Wheel pin 2) Km counter sensor 3) Right external spacer 4) Right oil seal 5) Right bearing 6) Wheel 7) Internal spacer 8) Left bearing 9) Left oil seal 10) Left brake disc 11) Right brake disc 12) Left external spacer 7-22 Release 00 2002-09 chap.
Cycle parts Atlantic 500 REMOVING THE FRONT WHEEL 5 Read carefully (PRECAUTIONS AND GENERAL INFORMATION). 1 CAUTION Take care not to damage the brake hoses, disc and pads when removing/refitting the wheel. 2 Place the motorcycle on the center stand. 1 WARNING Position a block or support under the motorcycle so that front wheel is free of the ground and that the motorcycle is stable and will not fall backward when the front wheel is removed.
Cycle parts Atlantic 500 CHANGING THE BEARINGS Read carefully (PRECAUTIONS AND GENERAL INFORMATION). 1 2 CAUTION Each time they are disassembled the bearings must be checked and, if necessary, renewed. Clean both sides of the hub with a cloth. Removal 3 Work from the left side of the vehicle: Insert a punch (not pointed) into the wheel hub and work on the right bearing inner ring (1), changing the contact points in rotation (90°) in order not to misalign the bearing. Remove the right bearing (1).
Cycle parts Atlantic 500 INSPECTION CAUTION Inspect the condition of all the components, especially those listed below. 1 Bearings Turn the inner ring (1) by hand; it should rotate without blocking and/or making any noise. There should be no axial play. Bearings that show signs of these problems must be replaced. CAUTION Apply grease to the balls (or rollers) at the side of each bearing, see (LUBRICANT CHART). This operation is not required of the bearing is of the self-lubricating type.
Cycle parts Atlantic 500 REFITTING THE FRONT WHEEL CAUTION Be careful not to damage the brake lines, disc and pads when refitting. Position the wheel between the fork rods. Insert the wheel pin (1) from the right side of the vehicle. Insert the spacer (2) between the hub and the right fork rod. Insert the spacer between the hub and the left fork rod. Screw in and tighten the wheel pin (1). 2 1 3 NOTE Perform this operation from the right side of the vehicle also.
Cycle parts Atlantic 500 REAR WHEEL 5 4 1 3 2 7 KEY 1) 2) 3) 4) 5) Complete wheel Spacer Oil retainer Brake caliper/exhaust support plate Nut chap.
Cycle parts Atlantic 500 REMOVING THE REAR WHEEL Read carefully (PRECAUTIONS AND GENERAL INFORMATION). 7 Place the motorcycle on the center stand. 5 WARNING Wait until the engine and exhaust muffler cool down completely. 3 6 Remove the exhaust muffler, see (REMOVING THE EXHAUST MUFFLER). Unscrew and remove the screw (5) that fastens the hose gland. Unscrew and remove the two screws (6) fastening the rear brake caliper (7). Free the rear brake caliper (7) from its support (3).
Cycle parts Atlantic 500 REMOVING THE EXHAUST MUFFLER Read carefully (PRECAUTIONS AND GENERAL INFORMATION). Place the motorcycle on the center stand. WARNING Wait until the engine and exhaust muffler cool down completely. 1 Loosen the clamp (1) using the relevant lock nut that fastens the exhaust muffler to the manifold. Unscrew and remove the three bolts (2) fastening the muffler to the support (3), being sure to keep the nuts. Remove the exhaust muffler (4). 3 2 4 2 chap.
Cycle parts Atlantic 500 INSPECTION CAUTION Inspect the condition of all the components, especially the ones listed below. 1 Bearings Rotate the internal ring (1) manually: there must be no catching or noise. There must be no end float. Any bearings not meeting these requirements must be renewed. CAUTION Apply grease to the balls (or rollers) at the side of each bearing, see (LUBRICANT CHART) . This operation is not required of the bearing is of the self-lubricating type.
Cycle parts Atlantic 500 1 8 2 4 5 3 6 8 7 5 3 7 9 9 KEY 1) 2) 3) 4) 5) 6) 7) 8) 9) Brake lever Brake fluid pump/tank Brake fluid tube Braking delaying device Brake caliper breather valve Tube union screw Brake calliper Brake pads Brake disc chap.
Cycle parts Atlantic 500 CHANGING THE BRAKE PADS Read carefully (PRECAUTIONS AND GENERAL INFORMATION). 4 Place the motorcycle on the center stand. NOTE Perform the following operations on both 1 sides. Unscrew and remove the screw (1). Unscrew and remove the two screws (2) and free the brake caliper (3). Still holding the brake caliper, remove the plate (4). Slide out the two pins (5). Remove the two pads.
Cycle parts Atlantic 500 CHECKING THE BRAKE DISC CAUTION This check must be done with the brake disc installed on the wheel. Make a visual check of the brake disc surface. If there are any lines or signs of wear, replace the disc, see (REMOVING THE BRAKE DISC). Check the brake disc for wear by measuring the minimum thickness in different points using a micrometer. If the minimum thickness is less than the limit value, even in a single point, replace the disc. Minimum brake disc thickness value: 0.
Cycle parts Atlantic 500 11 7 2 8 10 5 1 9 10 4 3 6 12 KEY 1) Brake lever 2) Brake fluid pump/tank 3) Brake fluid tube 4) Valve 5) Tube union screw 6) Brake calliper 7) Pad pin 8) Collar 9) Brake pads 10) Anti-vibration springs 11) Pad springs 12) Brake disc 7-34 Release 00 2002-09 chap.
Cycle parts Atlantic 500 CHANGING THE BRAKE PADS Read carefully (PRECAUTIONS AND GENERAL INFORMATION). 1 Remove the rear brake caliper, see (REMOVING THE REAR BRAKE CALIPER). Remove the collar (1). Slide out the pin (2). Remove the spring (3). CAUTION As the pads slide out, the vibration-damping plates will slide out with them. Remove the pads (4) (complete with vibration-damping plates (5)), sliding them out one at a time.
Cycle parts Atlantic 500 CHECKING THE BRAKE DISC CAUTION This check must be done with the brake disc installed on the wheel. Make a visual check of the brake disc surface. If there are any lines or signs of wear, replace the disc, see (REMOVING THE BRAKE DISC). Check the brake disc for wear by measuring the minimum thickness in different points using a micrometer. If the minimum thickness is less than the limit value, even in a single point, replace the disc. Minimum brake disc thickness value: 0.
Cycle parts Atlantic 500 STEERING 2 4 For information on checking and adjusting the steering, see (CHECKING AND ADJUSTING THE STEERING). 1 Removal Read carefully (PRECAUTIONS AND GENERAL INFORMATION). Remove the handlebar cover, see (REMOVING THE TOP HANDLEBAR COVER) and (REMOVING THE BOTTOM HANDLEBAR COVER). Position the motorcycle on its center stand, on a lift platform, so that the front wheel can overhang the front of the platform.
Cycle parts Atlantic 500 NOTE Perform the following operation from the left 11 side of the vehicle also. Unscrew and remove the two screws (11). Free the brake caliper (12) from the fork. 12 CAUTION Do not engage the front brake lever after removing the brake caliper; this may cause the caliper piston to leave its seat, allowing brake fluid to leak. 11 Unscrew and remove the two screws (13). Remove the brake oil pipe clamp plate (14). Free the piping and brake caliper from the fork.
Cycle parts Atlantic 500 INSPECTION OF THE BEARINGS CAUTION Check that the parts are in proper working order. Make sure that the area coming into contact with the balls (1) (on the rotating (2) and fixed (3) seats) is not damaged or excessively worn. If any damage or wear is found, replace the whole bearing. CAUTION Apply grease to the area coming into contact with the bearings in the two seats (2 and 3), see (LUBRICANT CHART).
Cycle parts Atlantic 500 1 21 2 6 4 3 4 7 6 13 3 11 14 7 15 2 12 5 16 17 8 11 13 24 14 22 15 24 9 16 17 23 19 18 10 20 19 20 KEY 1) Fork base 2) Fork clamp screws 3) Snap ring 4) Rubber cap 5) Seal plug 6) Brake pipe gland 7) “GACO” O-ring 8) Spring 9) Pumping element 10) Return spring 11) Bottom pad 12) Left rod 7-40 13) Dust guard gasket 14) Retaining ring 15) Gasket seal 16) Retainer cap 17) Bushing 18) Left wheel support 19) Washer 20) Bottom screw 21) Right rod 22) Right wh
Cycle parts Atlantic 500 CHECKING THE OIL LEVEL If fork “end of travel” is found, the level of the rod oil must be checked. Remove the front shield, see (REMOVING THE FRONT SHIELD). 2 1 NOTE To facilitate removal of the two seal plugs (3), they must both be removed at the same time. Remove the snap ring (1). Remove the plastic cap (2). Gently pump the fork until the two seal plugs (3) and O-rings (4) come out. NOTE Ensure that the O-rings are in proper working 2 order and if not, replace.
Cycle parts Atlantic 500 REMOVING THE ROD-WHEEL SUPPORT ASSEMBLY (with fork fitted) Place the motorcycle on the center stand. CAUTION Place a suitable support under the vehicle in order to prevent it from falling. Remove the front mudguard, see (REMOVING THE FRONT MUDGUARD). Remove the front wheel, see (REMOVING THE FRONT WHEEL). Remove the front shield, see (REMOVING THE INNER SHIELD). NOTE Perform the following operation from the left side of the vehicle also.
Cycle parts Atlantic 500 DISASSEMBLING THE ROD-WHEEL SUPPORT CAUTION Check the oil quantity. If less than 13.72 cu. in (225 cm3) top up or replace. Read carefully (PRECAUTIONS AND GENERAL INFORMATION). To disassemble the small parts: rubber cap (1), retaining ring (seeger) (2), seal plug (3) complete with O-ring (4) and spring (5), carry out the operations for (CHECKING THE OIL LEVEL) on the relevant wheel rod, omitting the last two steps (checking the oil level). CAUTION Danger of oil spillage.
Cycle parts Atlantic 500 CHECKING THE PARTS Rod The sliding surface must not be lined and/or scratched. If the lines are deep, replace the rod. Use a dial gauge to check that any curving in the rod is less than the limit value. If above the limit value, replace the rod. Curve limit: 0.007 in (0.2 mm). WARNING NEVER straighten a curved rod; this will weaken the structure of the vehicle, making it dangerous to use. Wheel support Make sure there is no damage and/or cracking and replace if necessary.
Cycle parts Atlantic 500 REAR SUSPENSION SPRING PRELOADING SETTING TABLE Adjusting ring nut Rotation (arrow A) Function Spring preload increase Rotation (arrow B) Spring preload decrease Attitude The vehicle is more rigid The vehicle is less rigid Recommended Smooth or normal roads kind of road Notes Rider and passenger Roads with uneven surface Solo rider REMOVING THE REAR SUSPENSION Read carefully (PRECAUTIONS AND GENERAL INFORMATION). Place the motorcycle on the center stand.
Cycle parts 7-46 Atlantic 500 Release 00 2002-09 chap.
aprilia s.p.a. via G.Galilei, 1 30033 Noale (VE) Italy tel. +39 041.5829111 fax +39 041.5829190 www.serviceaprilia.
